Investigation and prediction of central cracking in cross wedge rolling

Abstract Central cracking refers to the formation of internal cavities in cross wedge rolling (CWR) products. It occurs various materials such as aluminium/titanium alloys, steels and plasticine at room or elevated temperatures, driven by different central mechanisms. However, these mechanisms are still elusive, a unified predictive model is absent due complex stress states within workpiece, including triaxial states, cyclic loading severe shear effects. In this study, underlying fracture were revealed, robust damage with sound physical meanings was developed using lab-scale CWR finite element models. The billets built, allowing dies geometries rapidly 3D printed ductility efficiently manufactured. transiting from brittle ductile experimentally observed for first time specifically designed plasticine/flour composite samples varying ductility. corresponding physics-based proposed validated quantitatively 60 groups tests compared ten existing models/fracture criteria. This study effectively solves long-lasting problem industry enhances scientific understanding mechanics engineering applications.