Multi-Variant Analysis of the Cross Wedge Rolling Process for Producing Railcar Axles

This study investigates the cross wedge rolling (CWR) process for manufacturing a rail axle in a scale of 1:6. Three cases of the rolling process are modelled numerically: standard rolling, wasteless rolling and rolling from a preform. The rolling cases under analysis are compared in terms of material and energy consumption, forming loads as well as propensity to internal and external defect formation. Using the Cockcroft-Latham criterion and the limits of this criterion determined by the rotary compression test, an assessment was made of the propensity of the material to fracture during the rolling processes analysed. Based on numerical results, standard CWR is selected for experimental verification. Obtained experimental results confirm that CWR is an effective method for producing railcar axles that are free from both internal and external defects. The experimental and numerical results obtained confirm that cross wedge rolling technology can be successfully used under industrial conditions for the production of long axles or shafts.