Optimization of Material Utilization by Developing a Reliable Design Criterion for Tool Construction in Cross-Wedge Rolling

The massive forming industry in Germany produces around 1.4 million parts every year, which are mainly used in safety-relevant areas such as the automotive industry. The production of these parts requires a considerable amount of energy, much of which remains unused and causes high CO₂ emissions. An efficient approach to reduce these emissions and improve material utilization is cross-wedge rolling, which enables efficient material utilization but is limited by the so-called Mannesmann effect, which leads to unwanted material defects. This paper describes the development and validation of a safe design criterion for cross-wedge rolling tools in order to avoid material damage caused by the Mannesmann effect and thus increase resource efficiency in forging. Based on simulation-supported investigations and experimental tests, process maps are created for various materials. The validation is carried out both in an experimental test facility with real tools and in an industrial production facility, which leads to a significant reduction in excess material and CO₂ emissions. The results show that the full resource potential of cross-wedge rolling can be exploited by optimizing process parameters and tool geometries.