Cross rolling

Economic manufacturing of intermediate shapes with optimized mass

Cross rolling is a forming operation using wedge-shaped tools. Billets with a circular cross-section are placed between the two tool halves which are moving in opposite directiona. The tools contain the negative contour of the final workpiece shape. The radial penetration of the wedges into the billet and the redistribution of the material in axial direction cause a reduction of the initial diameter corresponding to the shape stored in the tool. The rolling process can be applied in the temperature range of cold, warm or hot forming.

Cross rolling processes allow economic manufacturing of intermediate shapes with accurately defined mass distribution for subsequent forming operations such as die forging with minimum flash. Besides the rolling of intermediate shapes, final components can be manufactured as well in near-net-shape quality. They can be produced for final machining or without further processing. The cross rolling process ensures high surface quality, constant processing allowances and low tolerances.

  • Cross rolling of hollow gear shafts
  • Cross rolling of super alloys in small series production
  • Cross rolling of light metals

  • Complete process chain using forming technology for manufacturing hollow gear shafts from billet sections
  • Process application with high-temperature resistant alloys
  • Feasibility studies using intermetallic phases
  • Process optimization in cross rolling of light metals
  • Reduction of tool cost
  • Cost-efficient application in small and medium-sized series
  • Determination of characteristic values for FEM simulation

Development of process chains for

  • Intermediate shapes for finishing by forming using minimum flash or flash-free die forging
  • Initial shaping followed by final machining
  • Finish forming without further machining

Using the following workpiece materials

  • Structural steels| case hardening steels | heat-treatable steels
  • High-grade structural steels | ferritic-pearlitic steels for precipitation hardening
  • Non-ferrous metals: Al – Ms – Cu – Ti
  • Gamma-titanium aluminides | super alloys

Development and evaluation of forming strategies

  • Market analysis| feasibility studies| Technological consultations
  • Staff training
  • Technology development| numerical simulation
  • Tool design | scheduling of technological operations
  • Tool construction | tool manufacturing
  • Manufacturing of prototypes
  • Support in start of production

Quality assurance

  • Determination of characteristic values before and after forming
  • Optimization of process parameters

Specific machine technology

  • Flat tool holder cross rolling machine FBQ 100/1600 with additional equipment for manufacturing of hollow parts (max. diameter of rolled part 100 mm, max. tool length 1,600 mm)
  • Round tool holder cross rolling machine RBQ 1000 (max. diameter of rolled part 200 mm, roll diameter 1,000 mm)
  • Axial-feed cross rolling machine AVQ 630 (max. diameter of rolled part 63 mm, roll diameter 630 mm)


  • 3D-CAD software: PTC/Creo
  • Finite element software: Forge / Simufact.Forming