A simulation model for tworoll cross wedge rolling (CWR) was presented by using threedimensional rigidplastic finite element method (FEM). The whole forming process of CWR, including knifing zone, guiding zone, stretching zone, and sizing zone, was simulated using the model in which dynamic adaptive remeshing technology for tetrahedral solid elements was used to fix element distortion. Based on the simulation results, the distributions of metal flow field, strain field, and damage field, and the geometry of the workpiece′s end were analyzed. These results could provide theoretical guidance for realizing net shaping and reasonable design of tools.
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