Experimental and numerical analysis of helical-wedge rolling process for producing steel balls

The helical-wedge rolling (HWR) process is a new metal forming technique for producing spherical parts of various dimensions. In this paper, the overall details of the HWR process are described and the important process parameters that control the HWR process are systematically discussed. A new experimental method, developed under laboratory conditions, showed that the HWR process can produce spherical steel parts (balls) with high manufacturing quality. Numerical simulations of the HWR process were carried out using a commercially available FEM software (Simufact) to show the stress, strain, and temperature distributions in the rolled balls. In addition, the variation of forces and rolling moments during the process are analyzed. Based on the experimental and numerical investigations, the HWR technique has been found to be a viable process for enhancing the quality and productivity of formed spherical products.

► The new method of balls forming by means of helical wedge rolling is presented in this paper. ► Obtained solution has many advantages in comparison to traditional balls forming method applied in industry. ► The scope of research consists of numerical simulations FEM and experimental tests.