Multi-wedge synchronous rolling by cross-wedge rolling is one of the most advanced methods that can form rolling railway axis. Its rolling quality mainly lies on inner transversal stress and shearing stress of rolling workpiece. In this paper, based on the rotated theory of multi-wedge rolling, through using Ansys/Ls-Dyna FEM software, multi-wedge synchronous rolling railway axis by cross-wedge rolling is simulated. It has been systemically researched that technical parameters effect transversal stress and shearing stress. In the meantime, the calculating model is verified by experiment. Through this study, It is obtained that the law of technical parameters effect on rolling railway axis by multi-wedge synchronous cross-wedge rolling. These research conclusions can provide scientific basis for rolling railway axis by multi-wedge synchronous cross-wedge rolling and rolling better quality.

The forming process of rolling workpieces with different end shapes with cross wedge rolling was simulated by the software Deform-3D. And combined with the principle of blank compensation method, the influence of process parameters on the volume of the stub bar of workpiece with flat end and circular-arc end was analyzed, and the method to effectively control the concavity of rolled piece end surface is brought forward by using circular-arc billet. According to the obtained research results, the volume of stub bar is in direct proportion to the spreading angle, and decreases at first and then increases with the increasing of the forming angle, and increases at first and then decreases with increasing of the area reduction, and increases at first and then keep approximately invariant with increasing of mill length. Finally, the feasibility of using circular-arc billet to reduce the concavity were verified by rolling experiment.

Aimed at preventing the problems of axial movement, step blemish and rolling overlap piece of skins which make from the imbalance of axial and tangential force because of asymmetry of parts in size and shape, the paper adopted finite element method (FEM) to simulate CWR technique of typical asymmetric shaft part, and analysis systematically axial force and axial displacement. Then we can judge axial offset by axial displacement of central point of billet. The results of the study indicate that FEM can manifest the axial deformation of asymmetric shaft parts in CWR, which provides theoretical foundation for the promotion of CWR technology in the application of asymmetric shaft parts manufacture.

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