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Flash‐reduced forging is a promising alternative for forging complicated high‐duty parts. With a new process chain, the ability to reduce the existing flash quota of complex high‐duty parts can make the difference in the competition and reduce the costs compared to flashless forging. The European Union is funding a research project which deals with the improvement of the forging sequence of a two‐cylinder crankshaft by using flash‐reduced forging. To increase the forecast quality of simulations using Finite‐Element‐Analysis for a future process chain design, the conventional existing process chain is simulated with FORGE3 and compared with industrial forging trials. Furthermore, a variation of simulation parameters has been used to get the significant influence parameters, fitting the results of these forging trials.

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In this paper the comparison of simulations of cross wedge rolling processes with real trials using flat cross wedge tools is presented. The investigated materials are titanium and bainitic grade steel. First simulations were used to find the suitable parameter combinations for the investigated materials. Afterwards tools were manufactured with these parameters and additionally with some variations to investigate a field of parameters around this range of parameter values. The purpose of these tests is to find geometrical and process parameters with which a stable cross wedge rolling process for bainitic grade steel and titanium is possible.

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