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Cross Rolling, Toothed Shaft, FEM, Experiment.


This paper presents a new concept for forming toothed shafts based on the cross-wedge rolling process (CWR). This method consists in using special inserts in the shape of flat
rack bars, which, acting on a billet, extrude material from tooth spaces to tooth points. These inserts are placed at the finish end of a wedge tool. Numerical calculations (based
on FEM) and experimental rolling tests unequivocally demonstrate the effectiveness of the proposed method for forming spur (straight-cut), helical, curved and herringbone
gear teeth.


Acta Mechanica Slovaca. Volume 15, Issue 2, Pages 50 – 58, ISSN 1335-2393


  A FEM Analysis of Cross-Wedge Rolling of Toothed Shafts


[1] Lange K. et al. Handbook of Metal Forming. Mc Graw-Hill Book Company 1985

[2] Fu X. P. and T. A. Dean. Past developments, current applications and trends in the cross wedge rolling process. International Journal of Machinery Tools Manufacture Design, Research and Application 1993 vol. 33, pp. 367-400
[3] Pater Z. A study of cross wedge rolling process. Journal of Materials Processing Technology 1998, vol. 80-81 pp. 370-375
[4] Pater Z. Cross-wedge rolling. Ed. Lublin University of Technology 2009 (in Polish)
[5] Pater Z. and J. Tomczak. Cross–wedge rolling of parts with non-circular cross section. Proceedings of the 24th International Manufacturing. Conference, IMC 24, Waterford Institute of Technology Ireland, 2007, pp. 1079-1086
[6] Holub J. Transverse hot rolling. Machinery 16 January 1963, pp. 129-133

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