A helical wedge rolling process for producing a ball pin

Abstract

Abstract The paper describes a new metal forming process called Helical Wedge Rolling (HWR). Combining the advantages of cross wedge rolling and skew rolling methods, this process allows for continuous forming of axisymmetric parts. HWR is characterized by high efficiency and low material losses. What may present a difficulty is the design of tools that will enable the formation of parts with required shape. To overcome this and ensure effective design, numerical modelling is performed. The paper describes the numerical modelling of a HWR process for a ball pin. The paper also presents the design of a stand for rolling tests (prototype helical-wedge rolling mill) and experimental results (obtained output: 30 pieces per minute).