The article presents the results of development and research of various technological schemes of the process of stamping by rolling cylindrical and conical rolls to obtain complex profile workpieces. It is shown that the achievement of significant dimensions of the various elements of the workpiece is possible by providing a directed flow of metal by changing the relative position of the roll and the workpiece. The most effective rolling operations are landing, settling, unloading, reverse and direct extrusion. The paper focuses on the analysis of operations of reverse and direct extrusion to obtain complex profile blanks with developed, including thin-walled elements. Since the technological capabilities depend on the deformability of the material, the analysis of the stress-strain state of the workpieces was performed using the method of grids, hardness measurement and microstructural analysis. The main result of the analysis was the construction of ways to deform the particles of the workpiece material in the coordinates "deformation intensity - stress index". Zones of blanks that are deformed in the conditions of "rigid" stress state are established, therefore for these zones the deformability of metals was assessed using the criteria of phenomenological theory. In addition, the assessment of deformability was also performed for areas with the maximum degree of deformation of the material. The manufacture of thin-walled elements of the workpiece, using the operation of reverse extrusion, is accompanied by the appearance of significant contact stresses. To prevent the roll from being pushed out of the workpiece and forming elements with a constant thickness, support rollers should be provided. In the case of direct extrusion, the increase in contact stresses requires the application of additional measures to increase the strength of the tool.

The article presents the results of development and research of the technological process of cold forming rolling of aluminum billets. The main obstacle to the implementation of such processes is the danger of destruction of materials, which necessitated the study of the stress-strain state, plasticity and assessment of the deformability of the workpiece material. To experimentally determine the ductility of metals, a rolling method was developed, according to which the deformation of the free side surface of the cylindrical sample occurs under uniaxial tension. Increasing the degree of deformation and bringing the material to fracture is provided due to the increase in the radii of the rolls during rolling and deformation of the sample on the wedge. Analysis of the stress-strain state of the free side surface of the cylindrical workpiece was performed by the finite element method, which used a specialized engineering software package DEFORM 3D. As a result, a significant inhomogeneity of the stress-strain state in the deformation zone is established. The most severe stress state is observed on the free side surfaces of the workpiece, which causes the danger of its destruction in this area. The dependence between the relative compression of the workpiece during rolling and the intensity of deformation on its side surface is obtained, which allows to determine the limiting thickness of the workpiece before destruction. As a result of the assessment of the deformability of aluminum alloys during cold rolling, using the curves of limit deformations and the scalar criterion of deformation, the limits to the destruction of the intensity of deformation and the limit value of the relative compression of the workpiece. The use of constructed models makes it possible to determine the value of the used plasticity resource at intermediate stages of rolling.