An Innovative Method for Forming Balls by Cross Rolling

The paper describes an innovative cross rolling method that enables the production of six balls at the same time, each ball with a diameter of 100 mm. The principle of the proposed rolling technique is discussed and the tools used in this forming process are described. Two variations of the proposed method for producing balls were investigated, one performed with the use of flat tools and the other with the use of two rolls. Results of the numerical modelling are discussed. They clearly demonstrate that the proposed method can be used to produce balls with large diameters. Rolling experiments were performed under laboratory conditions to produce 40 mm diameter balls, i.e., in the 1:2.5 scale. The experimental findings show a good qualitative agreement with the numerical results.