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<p>Small diameter balls are used in various industries, such as bearings, electronics, and energy. Single roller–cross wedge rolling (SR-CWR) is a method with the potential for forming small-sized parts. In this study, the SR-CWR process was developed for producing small-diameter metal balls. Finite element (FE) simulations were conducted to analyze the distributions of stress, strain, rolling force, and torque during the forming process. Furthermore, Φ3.1&#xa0;mm AISI 304 stainless steel balls with a dimensional error of less than 3% were successfully formed using an experimental single-roller mill, showing good agreement with the FE simulation results. The surface roughness near the poles was higher than at the equator, due to differences in metal flow intensity. The overall hardness of the rolled steel ball was notably improved. The surface layer exhibits higher hardness than the core, and the pole regions are harder than the equator, consistent with the observed strain distribution. Additionally, the SR-CWR technique was extended to form metal balls of different materials and sizes, covering three different specifications. These results highlight the SR-CWR process as a highly suitable approach for manufacturing small-diameter ball parts, with significant potential for producing microscale ball components in the future.</p>

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Experimental and numerical study on single roller–cross wedge rolling for small diameter metal balls

  • 期刊论文

  • 发表日期：

    2025年8月13日

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  • Xuan Wang,
  • Baoyu Wang,
  • Wei Li,
  • Jiapeng Wang,
  • Haojie Zhang

摘要

Small diameter balls are used in various industries, such as bearings, electronics, and energy. Single roller–cross wedge rolling (SR-CWR) is a method with the potential for forming small-sized parts. In this study, the SR-CWR process was developed for producing small-diameter metal balls. Finite element (FE) simulations were conducted to analyze the distributions of stress, strain, rolling force, and torque during the forming process. Furthermore, Φ3.1 mm AISI 304 stainless steel balls with a dimensional error of less than 3% were successfully formed using an experimental single-roller mill, showing good agreement with the FE simulation results. The surface roughness near the poles was higher than at the equator, due to differences in metal flow intensity. The overall hardness of the rolled steel ball was notably improved. The surface layer exhibits higher hardness than the core, and the pole regions are harder than the equator, consistent with the observed strain distribution. Additionally, the SR-CWR technique was extended to form metal balls of different materials and sizes, covering three different specifications. These results highlight the SR-CWR process as a highly suitable approach for manufacturing small-diameter ball parts, with significant potential for producing microscale ball components in the future.