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A novel single-roller multi-wedge cross rolling method for stable and precise forming steel balls
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DOI：10.1016/j.cirpj.2026.07.015.png)
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Abstract
En 中文
Conventional steel ball rolling processes suffer from defects such as incomplete filling and surface scratches, and often exhibit limited forming stability. To address these issues, a single-roller multi-wedge cross rolling (SRMCR) process is proposed for simultaneously forming multiple balls. A theoretical model based on the principle of volume conservation is established to determine key die geometric parameters and precisely control billet volume during forming. Finite element simulations are conducted to investigate the metal flow behavior, stress-strain evolution and damage distribution. The results show that asynchronous metal flow occurs along the rolling direction during the SRMCR process. The strain distribution exhibits clear symmetry and consistent deformation among adjacent balls, indicating stable forming behavior. Distributions of stress triaxiality, the Lode parameter, and Cockcroft-Latham damage reveal that the pole and connecting neck regions exhibit higher damage tendencies than the core region. Process parameter analysis indicates that a diameter expansion ratio of 110% combined with linear wedge-height variation provides the optimum forming conditions for 6 mm steel balls. Validation experiments produce 6 mm steel balls with complete filling, no obvious scratches, and significantly improved mechanical properties. Multi-ball experiments achieve stable simultaneous forming of up to eight balls with a material utilization exceeding 90%, demonstrating good scalability and industrial applicability. Microstructural analysis indicates that the strengthening mainly results from severe plastic deformation-induced dislocation accumulation and subgrain formation. The proposed process overcomes the limitations of conventional ball rolling processes and provides an effective approach for the precision cold forming of small-diameter steel balls.
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