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The results of theoretical and experimental research on splitting without waste, realized basing on cross-wedge rolling method are presented in this paper. The analyzed process is connected with rolling of a V-shape groove on a split billet circumference, and later with rotary bending causing material separation. A short characteristic of splitting methods of metal bars with circular cross-sections was made, with pointing out features crucial in the aspect of manufacturing process shortening and material savings. In theoretical analysis, based on simulations by means of finite element method, basic models of metal cracking (brittle and ductile) were applied. During calcula¬tions, the following process parameters were changed: forming angle a, bending angle 9 and reduction ratio Ar. The achieved results allowed for a precise analysis of the splitting process within the scope of: state of strain, kinematics of flow, force parameters, state of stresses and type of cracking of the split material. Experimental verification was conducted with the application of a flat-wedge rolling mill, equipped with specially designed and made tools sets. During rolling, the basic force parameters and kinematics parameters were regis¬tered. On the basis of experimental research, the influence of the analyzed parameters on the surface of splitting was estimated and scope of parameters guaranteeing the assumed quality of the product was given. The comparison of theoretical and experimental results showed good conformity.
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