A Computational and Experimental Study of Cold Rolling of Aluminum Alloys With Edge Cracking

2004 ◽  
Vol 126 (1) ◽  
pp. 74-82 ◽  
Author(s):  
S. Ghosh ◽  
M. Li ◽  
D. Gardiner
Keyword(s):  
Finite Element ◽  
Aluminum Alloys ◽  
Cold Rolling ◽  
Experimental Studies ◽  
Rolling Process ◽  
Rolled Strip ◽  
Damage Models ◽  
Friction Laws ◽  
Model Predictions ◽  
Edge Cracking

This paper identifies various modeling issues that are necessary for successful simulation of the cold rolling process by comparing it with experiments on aluminum alloys. It combines considerable experimental studies with finite element simulations using the ABAQUS/Explicit commercial finite element code to identify and evaluate modeling parameters, such as the material properties and friction laws. Damage models are incorporated in the numerical simulations by using plasticity with damage variables e.g., the Gurson-Tvergaard model with evolving porosity and Cockcroft-Latham with damage in terms of plastic work. The 3D model predictions are compared with predictions from 2D models to understand the limitations of 2D simulations in predicting the stresses, strains and evolving damage in the rolled strip.

Finite Element Analysis of Thin Strip Profile in Asymmetric Cold Rolling Considering Work Roll Crossing and Shifting

2014 ◽  
Vol 1061-1062 ◽  
pp. 515-521 ◽  
Author(s):  
Abdulrahman Aljabri ◽  
Zheng Yi Jiang ◽  
Dong Bin Wei
Keyword(s):  
Finite Element ◽  
Cold Rolling ◽  
Finite Element Model ◽  
Rolling Force ◽  
Element Model ◽  
Work Roll ◽  
Rolling Process ◽  
Thin Strip ◽  
Asymmetric Rolling ◽  
Element Analysis

Cold rolled thin strip has received a great deal of attention through technological and theoretical progress in the rolling process, as well as from researchers who have focused on some essential parameters of strip such as its shape and profile. This paper describes the development of a 3-D finite element model of the shape of thin strip during cold rolling to simulate the cold rolling of WCS (work roll crossing and shifting) in asymmetric rolling. This finite element model considers the asymmetrical rolling parameters such as variations in the diameters of the rolls and the crossing angle as the work roll shifts on the strip during cold rolling. The shape and profile of the strip are discussed in the asymmetrical and symmetrical rolling conditions, while the total rolling force and distribution of stress are discussed in the case where the roll cross angle and axial shifting roll changes. The results can then be used to control the shape and profile of thin strip during rolling.

scholarly journals Comprehensive Analysis of Metal Deformation Law Based on Numerical Simulation of Cold Rolling Process

2020 ◽  
Author(s):  
Zhu-Wen Yan ◽  
Bao-Sheng Wang ◽  
He-Nan Bu ◽  
Hao Li ◽  
Lei Hong ◽  
...  
Keyword(s):  
Finite Element ◽  
Cold Rolling ◽  
Finite Element Model ◽  
Equivalent Stress ◽  
Element Model ◽  
Work Roll ◽  
Rolling Process ◽  
Efficiency Coefficient ◽  
Strip Rolling ◽  
Research Results

Abstract Through taking the cold rolling process as the research object, the three-dimensional finite element model of the strip rolling process is established by using ANSYS/LS-DYNA software. The simulation results of the finite element model have a good fit with the actual production data. The rolling process is dynamically simulated, and the distribution curves of important rolling parameters such as equivalent stress, control efficiency coefficient, transverse rolling pressure, lateral thickness and work roll deflection is obtained. The research results of this paper have strong practicability for the process control of cold strip rolling mill. The research results have certain guiding significance for the development and optimization of the rolling control system.

scholarly journals Cold Rolling Texture Prediction Using Finite Element Simulation with Zooming Analysis

Materials ◽  
2021 ◽  
Vol 14 (22) ◽  
pp. 6909
Author(s):  
Honghao Wang ◽  
Sheng Ding ◽  
Tom Taylor ◽  
Jun Yanagimoto
Keyword(s):  
Finite Element ◽  
Cold Rolling ◽  
Manufacturing Industry ◽  
Rolling Texture ◽  
Rolling Process ◽  
Metal Plate ◽  
Recrystallization Temperature ◽  
Analysis Method ◽  
Metal Plates ◽  
Cold Rolling Texture

Cold rolling is widely employed in the manufacturing industry for the production of metal plates. In the cold rolling process, the thickness reduction of the metal plate under the recrystallization temperature generates severe anisotropy; this influences the subsequent forming processes. Therefore, the generation and prediction of metal plate anisotropy during cold rolling is a highly interesting research topic involving upstream studies of sheet metal forming. In this study, using the finite element method with zooming analysis, we established an efficient elastic–plastic analysis method to predict the metal plate texture after cold rolling. This method for cold rolling texture prediction was confirmed by comparing the experimental and simulation results of cold rolling for an S45C plate with a body-centered cubic lattice. Further, the numerical analysis method proposed in this study can contribute to the study of anisotropy as an alternative to experimental approaches.

Numerical Simulations and Design of Shearing Process for Aluminum Alloys

2004 ◽  
Vol 127 (3) ◽  
pp. 612-621 ◽  
Author(s):  
Aniruddha Khadke ◽  
Somnath Ghosh ◽  
Ming Li
Keyword(s):  
Aluminum Alloys ◽  
Numerical Simulations ◽  
Process Parameters ◽  
Design Method ◽  
Experimental Studies ◽  
Burr Formation ◽  
Design Parameters ◽  
Arbitrary Lagrangian Eulerian ◽  
Damage Models ◽  
Commercial Code

This work combines experimental studies with finite element simulations to develop a reliable numerical model for the simulation of shearing process in aluminum alloys. The critical concern with respect to product quality in this important process is burr formation. Numerical simulations are aimed at understanding the role of process variables on burr formation and for recommending process design parameters. The commercial code ABAQUS-Explicit with the arbitrary Lagrangian-Eulerian kinematic description is used in this study for numerical simulations. An elastic-plastic constitutive model with experimentally validated damage models are incorporated through the user subroutine VUMAT in ABAQUS, for modeling deformation and ductile fracture in the material. Macroscopic experiments with microscopic observations are conducted to characterize the material and to calibrate the constitutive and damage models. Parametric study is done to probe the effect of process parameters and finally, a genetic algorithm (GA) based design method is used to determine process parameters for minimum burr formation.

Prediction of Edge Crack in Cold Rolling of Silicon Steel Strip Based on an Extended Gurson–Tvergaard–Needleman Damage Model

2015 ◽  
Vol 137 (2) ◽  
Author(s):  
Quan Sun ◽  
Jianjun Chen ◽  
Hongliang Pan
Keyword(s):  
Cold Rolling ◽  
Edge Crack ◽  
Steel Strip ◽  
Damage Model ◽  
Rolling Process ◽  
Reduction Ratio ◽  
Shear Damage ◽  
Gtn Damage Model ◽  
Edge Cracking ◽  
Roller Radius

Edge cracking is commonly observed in cold rolling process. However, its failure mechanism is far from fully understanding due to the complex stresses and plastic flow conditions of steel strip under the rolling condition. In this paper, an extended Gurson–Tvergaard–Needleman (GTN) damage model coupled with Nahshon–Hutchinson shear damage mechanism was introduced to investigate the damage and fracture behavior of steel strip in cold rolling. The results show that extended GTN damage model is efficient in predicting the occurrence of edge crack in cold rolling, and the prediction is more accurate than that of the original GTN damage model. The edge cracking behavior under various cold rolling process parameters is investigated. It comes to the conclusion that edge crack extension increases with the increase of the reduction ratio, tension and the decrease of the roller radius and friction coefficient. The influence of shear damage becomes more significant in rolling condition with a larger reduction ratio, smaller roller radius, lower friction force, and tension.

Finite Element Simulation Analysis of Multi-Stands Three-Roller Cold Rolling Process for Double Metal Composite Seamless Steel Tube

2013 ◽  
Vol 470 ◽  
pp. 197-204 ◽  
Author(s):  
Xian Kang Wang ◽  
Jin Duo Ye ◽  
Xu Ma ◽  
Qian Qian Tian ◽  
Xue Li ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Cold Rolling ◽  
Rolling Process ◽  
Steel Tube ◽  
Metal Composite ◽  
Element Analysis ◽  
The Finite Element Analysis ◽  
Seamless Steel Tube ◽  
Seamless Steel

The numerical simulation of the Y-type three-roller two stands cold rolling stainless steel/carbon steel double metal composite seamless steel tube process was conducted through the finite element analysis of the elastic-plastic by applying the MSC.MARC software. Based on the numerical simulation, the character of stress and strain distribution parameters during the Y-type three-roller two stands cold rolling were obtained by the finite element analysis, and acquired the section pass deformation figure. The distribution of the axial stress, circle stress and radial stress were drawn below the Y-type mill along the circle. The mechanism of the tube cold rolling process and the effect of the forming steel tube both the diameter and wall thickness accuracy were explained according to the stress distribution. The results of the research can be applied to the design of the technical parameters in the forming process.

Finite Element Analysis on Chattering in Cold Rolling and Comparison With Experimental Results

2015 ◽  
Vol 137 (6) ◽  
Author(s):  
Reza Mehrabi ◽  
Mahmoud Salimi ◽  
Saeed Ziaei-Rad
Keyword(s):  
Finite Element ◽  
Cold Rolling ◽  
Rolling Process ◽  
The Finite Element Method ◽  
Element Analysis ◽  
Mill Stand ◽  
Predicted Values ◽  
Lumped Masses ◽  
Roll Gap ◽  
Good Agreement

In this paper, the chattering phenomenon in cold rolling is investigated in reference to the finite element method (FEM). The structure of the mill stand is modeled as a system of linear springs and lumped masses while the rolling process is modeled utilizing an implicit FEM. Assembling the two models makes it possible to detect the chatter during the rolling process. The assembled model is capable of perceiving variations in forces generated during the process that deflects the structure of the mill leading to variations at the roll gap and the roll speed. The influences of some rolling parameters on chatter vibration are investigated. Predicted values of the model are in good agreement with that of the experiments as well as the values obtained by other researchers.

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