An explicit dynamic finite element model is used to analyze the tribological behavior of the cross-wedge rolling (CWR) of tubular structures. Cross-wedge rolling is a manufacturing process used to form axisymmetric parts by the relative motion of two opposing hardened dies. To date, the CWR process has been used to form only solid parts. In the present investigation, results are presented for the counteraction of flat dies that are used to deform tubular structures. By combining, numerical and experimental evidence, a critical forming parameter is developed which predicts the critical rolling conditions for the CWR forming of tubular structures. This parameter combines the effects of friction, wall thickness to radius reduction, and tube hardness.

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