Material fracture is a serious problem in cross wedge rolling (CWR). Finding new solutions for material fracture prevention in CWR processes presents a technological challenge for researchers these days. This paper presents a new approach to the problem of material fracture, which investigates a not previously undertaken aspect concerning the influence of the cross wedge rolling method on the development of internal cracks. CWR rolling methods in which two tools are used (two flat wedges, two roll wedges, roll wedge-concave segment, two concave wedges) were analysed. In addition, the effect of the number of moving tools on material fracture in CWR is investigated. Material fracture is predicted by a novel hybrid fracture criterion. In this paper, FE simulations were used to determine the value of the hybrid fracture criterion. Experimental studies were used to validate the built numerical model. The conducted research has shown that with the increase in the ovalization of the cross-section of the rolled forging, which depends on the rolling method and the number of moving tools, the degree of damage to the forging increases. The highest degree of damage occurs during the flat wedge rolling method, in which only one wedge is moving. The lowest degree of damage occurs when rolling with two moving concave wedges. The most important conclusion of the study is that changing the rolling scheme from the least favourable to the most favourable one allows to reduce the degree of forgings damage twice.

材料断裂是楔横轧（CWR）中的一个严重问题。如今，在 CWR 工艺中寻找防止材料断裂的新解决方案对研究人员来说是一项技术挑战。本文提出了一种解决材料断裂问题的新方法，该方法研究了以前未进行过的有关楔横轧方法对内部裂纹发展的影响的方面。分析了使用两种工具（两个平楔、两个滚楔、滚楔-凹段、两个凹楔）的 CWR 轧制方法。此外，还研究了移动工具数量对 CWR 材料断裂的影响。通过一种新的混合断裂准则预测材料断裂。在本文中，有限元模拟用于确定混合断裂准则的值。实验研究用于验证所建立的数值模型。进行的研究表明，随着轧制锻件横截面椭圆度的增加，取决于轧制方法和移动工具的数量，锻件的损坏程度增加。最严重的损坏发生在平楔轧制方法中，其中只有一个楔子在移动。当用两个移动的凹楔滚动时，损坏程度最低。该研究最重要的结论是，将轧制方案从最不利的转变为最有利的，可以使锻件损坏程度降低两倍。这取决于轧制方法和移动工具的数量，锻件的损坏程度增加。最严重的损坏发生在平楔轧制方法中，其中只有一个楔子在移动。当用两个移动的凹楔滚动时，损坏程度最低。该研究最重要的结论是，将轧制方案从最不利的转变为最有利的，可以使锻件损坏程度降低两倍。这取决于轧制方法和移动工具的数量，锻件的损坏程度增加。最严重的损坏发生在平楔轧制方法中，其中只有一个楔子在移动。当用两个移动的凹楔滚动时，损坏程度最低。该研究最重要的结论是，将轧制方案从最不利的转变为最有利的，可以使锻件损坏程度降低两倍。