Study on roll-cutting forming method of conical end blank for cross wedge rolling (CWR) without stub bar

Using conical end blanks is an effective method to improve the concave defects of cross wedge rolling, while the common method to get conical end blanks is machining, still causing material loss. Aimed at this situation, this paper proposes a roll-cutting forming method of conical end blanks based on metal-plastic forming. In order to clarify the rollcutting forming mechanism of the conical end, the displacement field and strain field variation during the forming process of the conical end are analyzed based on finite element simulation analysis, and the metal flow during the roll-cutting process is obtained. Moreover, the conical end blank formed by roll-cutting is sent to cross wedge rolling, the results verify the feasibility of roll-cutting conical end blank used for cross wedge rolling without stub bar.