The article analyzes the stress-strain state in the zone of plastic deformation during special caliber rolling. The principle of caliber rolling technology is described, which makes it possible to combine shear and compression deformations in the cross-section of metals, alloys, and metal-matrix composites. The analysis results of stresses and strains during shear rolling in a diamond pass, which included compressive strains that had not been considered in previous studies, revealed that localization or point inversion of stresses and strains is observed in the plastic deformation zone. Stress and strain are localized along the minor and major diagonals of the diamond pass.

The article presents an analysis of the stress state of workpieces during upsetting of workpieces with an additional shear. For the analysis, the slip line method and the finite element method were used. A schematic diagram of upsetting in dies with “floating” elements, contributing to the implementation of additional shear, reduction of barreling, inhomogenous deformation and contour tensile stresses, is presented. The analysis of the research results showed that during upsetting of workpieces with additional shift forces, tensile stresses on the side surface of the workpieces decrease, which excludes the appearance of cracks on the side surface of the samples, especially when processing low-plastic alloy steels and alloys, and also reduces the barreling of the side surface.

The study of the stress state and power parameters when pulling workpieces in a special die with an inclined working surface at various shapes of the plastic deformation zone and geometric parameters of the special die was conducted. The distinctive feature of the proposed special die and the metal treatment process in the working channel of this die was described. The theoretical provisions and assumptions from the fundamental theory of plasticity and metal forming were used. The influence of the intensity of shear deformations on the stress state and force at the angles of inclination of the working surface of the die within 45–20°, the value of the ratio of the diameter of the workpiece to the length of the inclined surface d/z=1.5–2.0 was investigated. The optimal d/z ratio was determined by the method to a rigid punch indenting a rigid-plastic half-space, as well as by the method of strain energy. The field of slip lines and hodographs of velocities for various shapes of the deformation zone and geometric parameters of a special die were constructed. Based on the constructed slip line fields and velocity hodographs, the mean stress and stress components at the nodal points of the slip line field with the compilation of the equilibrium equations for all forces applied to the plastic zone were calculated. The study of the influence of contact friction between the working surface of the die channel and the workpiece on the stress state and power parameters during pulling was carried out. It was revealed that the optimal ratio d/z=1.5 and the optimal angle of inclination of the working channel of the die α=20°. It was found that for these parameters in the zone of plastic deformation, mainly significant compressive stresses act, which favorably affect the obtaining of a homogeneous and refined microstructure, and also exclude the appearance of anisotropy due to the implementation of maximum shear deformations in the workpiece.