Shaping curve of the right-angle step for a cross wedge rolling elliptical shaft

A rotation formula which indicates the big end radius of the spiral declined cone changing with the rotation angle of rolled pieces for an elliptical shaft was proposed according to the process characteristics of cross wedge rolling.The volume formula for each stage was obtained by analyzing the shaping process.The shaping curve of the right-angle step in cross wedge rolling was derived from the volume balance principle.Finally,the shaping process of the elliptical shaft was simulated with the rigid-plastic FEM software Deform-3D.Excellent simulation results verified the correctness of the shaping curve.