Abstract
The paper presents the simulation of the radial-shear rolling process in two technological routes. The direct route involved the repeated rolling of the workpiece in the second pass. In the reverse route, the rolls were rotated in the opposite direction in the second pass, and the workpiece was captured at the exit from the rolls. The analysis of the shape change showed that the reverse rolling process resulted in the complete rolling over of the helical surface formed in the first pass. The analysis of the stress-strain state and the microstructure evolution revealed that the direct rolling process resulted in a gradient structure with fine grains on the bar surface and elongated grains in the axial zone, while the reverse rolling process allowed for a more uniform distribution of grain size across the cross-section. Additionally, it was found that the reverse rolling route allowed for a greater processing of the axial zone due to thedeeper penetration of plastic deformation into the workpiece. The final choice of the deformation route will depend on the desired outcome, whether it is a uniform or gradient structure across the bar.