In this study, the effects of various rolling conditions, such as inclined angle, offset angle, roll shapes, etc., upon the depth of the spiral marks on the surface of the rolled product and the rolling forces are discussed numerically by the finite element method. Experiments using a self-designed testing machine with work-rolls of three different kinds of roll shapes were conducted. The depth of the spiral marks was measured. From the comparisons between the analytical and experimental results, it is known that a smoother surface on the rolled product can always be obtained with convex-shaped rolls. Whereas, prominent spiral marks probably appear for two-stage conical rolls and spherical-headed rolls under an ill-set rolling condition. These analytical and experimental results can offer useful knowledge for the design of the roll shapes and the pass schedule during three-roll planetary rolling processes.
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