Finite element analysis and experiment on multi-wedge cross wedge rolling for asymmetric stepped shaft of C45

A rigid-plastic finite element method (FEM) simulation model for a multi-wedge cross wedge rolling (MCWR) was developed to analyze an asymmetric stepped shaft. To evaluate the MCWR process and better understand its deformation characteristics, the material flowing mechanisms, temperature distributions, strain and rolling force were analyzed. The correctness of the finite element simulation is experimentally verified. Numerical simulations and experiments led to the following conclusions: when α=36° and β=7.5°, the quality of the work piece can be significantly improved. Finally, the development of the asymmetric stepped shaft is applied to industrial production.