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Simulation on the rolling process of pairs of cross wedge rolling shaft Using COMSOL


Under the Guidance of Dr. Patil Basavaraj V Dept of IP & E
Submitted By Deepak Kothari

Introduction to CWR

The CWR is a rotary forming process, consists
of the forming of forging by means of wedge-shaped tools that are fixed on the mill rolls with the same rotary direction.
In CWR process, there are five stages in the work piece deformation process corresponding to five zones of the wedged tool geometry, i.e., knifing, guiding, stretching, shaping, and sizing.

Knifing zone, is mainly to shape a V-shaped groove. whose height starts at zero and increases to the total reduction of height, and drives the billet.
Guiding zone, the tool geometry has no change to obtain a uniform V-shaped groove around the work piece surface.
The stretching zone is a very important part of the CWR tool. The crucial parameters in this zone are the forming angle and the stretching angle .
The uniform dimension and surface quality of the work piece can be obtained in the last zone, the sizing zone.
The shaping zone is a transition stage between stretching and sizing. where an accurate shoulder can be formed.

Literature review

A simulation model for cross wedge rolling (CWR) was presented by using three-dimensional rigid- plastic finite element method (FEM).
The forming process of CWR, including knifing zone, guiding zone, stretching zone, and sizing zone, was simulated using the model in which dynamic adaptive remeshing technology for tetrahedral solid elements was used to fix element distortion.

by WANG Min-ting,
LI Xue-tong ,
DU Feng-shan.

Problem identification

To simulate the rolling process of cross wedge rolling and to analysis the stress field of the rolling at the stage of stretcher

COMSOL MULTIPHYSICS is a finite-element based program for stimulating unlimited Multiphysics and single-physics application interfaces, complete control over meshing, and powerful solvers.
It contains built in application modes and boundary settings for the modeling of acoustic wave propagation in solids and stationary fluids. Also models aeroacoustic application in moving fluids.


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