<p>The geometry of the tool’s forming surface is an important factor influencing the course of cross wedge rolling (CWR). Three different shapes of the tool’s lateral surface were considered, i.e. flat (standard), convex and concave. Experiments were conducted, demonstrating that the use of wedge tools with convex and concave forming surfaces resulted in decreased force and energy parameters as well as reduced crack formation in the axial zone of the workpiece. To account for the observed beneficial effects of using convex and concave tools, the experimental cases of CWR were modelled numerically using the Simufact Forming software. The effect of the tool’s forming surface shape on the forming loads, strain, stress, material temperature, and material fracture was examined in detail. The problem of material fracture was examined using eight different criteria of material fracture, which additionally helped determine the criterion that yielded the most accurate results regarding the formation of internal cracks in the workpiece.</p>