Elasto-Plastic Deformation Process of Cold Rolling (original) (raw)
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Journal of Al-Azhar University Engineering Sector
Metal rolling processes are usually subjected to continuous development for increasing the efficiency of metals industry and broadening the applicability of soft metals in the structural applications. During this study, cold plate rolling have been conducted under different conditions. Particularly, the rolling power and the resulted separating force have been analyzed after changing the roll diameter, the draft thickness, and the lubricant type. It was observed that, decreasing the reduction by pass and reducing the roll diameter could minimize the need for high power during operation. It was also noticed that, among the different experiments, using olive and paraffin oil as lubricant at the roll-metal surface show a significant effect on reducing the power consumption and increasing the rolling process efficiency in a high agreement with the mathematical modeling.
Indian Journal of Engineering and Materials Sciences
The present paper aims to identify a sequence of bulk-deformation processes able to produce sufficient quantities of ultra fine grained volume. Samples of aluminium Al 1100 alloy (98.41% Al) are subjected to repetitive equal channel angular pressing (ECAP) at room temperature, repeated up to eight passes. Severely plastic deformed specimens are cold rolled in thin strips which are subjected to structural characterization, calorimetric evaluation and mechanical testing with the aim of monitoring microstructural evolution. The X-ray diffraction studies and differential scanning calorimetry tests reveal the influence of cold rolling on ECAP'd samples, while tensile testing reveal marked strength increases with the number of rolling passes. Finally, an alternative technology is introduced which is easy to implement in metallurgical industry in order to provide large amounts of nanostructured strips.
Finite Element Simulation of Hot Rolling for an Aluminium 2024 Plate
Numerical simulation has become an important tool in the rolling industry. The use of two dimensional rolling model is quite common in Aluminum industries. In the present work A two dimensional elasto-plastic Finite Element model for hot rolling of an Aluminum plate has been developed. This model is used to study the behavior of the material under different values of coefficient of friction, roller diameter and initial thickness of the plate for attaining a specified final thickness of the rolled plate. The effect of coefficient of friction, initial thickness of plate and roller radius on maximum stress, equivalent plastic strain and reaction force has been studied. The current work has been carried out using the Finite Element software ABAQUS 6.10 (Explicit).
2014
The present paper aims to identify a sequence of bulk-deformation processes able to produce sufficient quantities of ultra fine grained volume. Samples of aluminium Al 1100 alloy (98.41% Al) are subjected to repetitive equal channel angular pressing (ECAP) at room temperature, repeated up to eight passes. Severely plastic deformed specimens are cold rolled in thin strips which are subjected to structural characterization, calorimetric evaluation and mechanical testing with the aim of monitoring microstructural evolution. The X-ray diffraction studies and differential scanning calorimetry tests reveal the influence of cold rolling on ECAP’d samples, while tensile testing reveal marked strength increases with the number of rolling passes. Finally, an alternative technology is introduced which is easy to implement in metallurgical industry in order to provide large amounts of nanostructured strips.
FEM Analysis of Effect of Rolling Parameters on Cold Rolling Process
Bonfring
A FEM simulation study was carried out to investigate the influence of the rolling parameters on the rolling process. Using commercial FEM software, ABAQUS, a number of cases were studied. In this paper, a two-dimensional Elastic-plastic finite element model to simulate the cold rolling of thick strip with different roll angular velocity and roll diameter models is described. The angular velocity of the rigid rolls ranged from 30 to 480 revolutions per minute (r.p.m.) and the rigid roll diameter ranged from 100 to 300 mm. The initial feeding speed of the plate and friction was kept constant, thus causing a slip between the plate and the roll surfaces. The main interest of this study is to see whether the speed of the rolls and the diameter of the rolls have any influence on the contact pressure and the residual stress in cold rolling process. The roll speed is an easily controlled operational parameter which may be used to enhance the process and the quality of the final products by changing the roller diameter and see the effect of stress and contact pressure on the thick plates strip is new one.
Parametric Study of Hot Rolling Process by the Finite Element Method
2009
Abstract. In the present investigation, a hot rolling process of AA5083 aluminum alloy is simulated. The approach is based on the thermo-mechanical analysis of the problem using the Finite Element Method (FEM). The temperature distribution in the roll and the slab, the stress, strain and strain rate elds, are extracted throughout a transient analysis of the process.
In this paper, the authors have developed a ®nite element model to establish a heat transfer ®nite element model and a three-dimensional large deformation thermo elastic±plastic ®nite element model, which is then coupled to form a complete theoretical model including heat transfer. In this theoretical model, the two variables of element deformation and temperature variation are placed in a variable matrix. The thermo elastic±plastic stiffness matrix and heat transfer stiffness matrix are placed in the same expansion stiffness matrix. Furthermore, a three-dimensional numerical simulation model of metal rolling formation is developed from the theoretical model. The numerical simulation model developed in this paper was used to simulate aluminum strip rolling. Simulation of the rolling process of aluminum strips in cold rolling and hot rolling under different reductions of the strip were conducted to obtain the effects of different reductions of the strip on rolling, and obtain related reference date for the practical rolling process. The simulation results were compared with experimental values to verify the feasibility of the theoretical model and numerical simulation model established in this study. The simulation presented in this paper indicates that regardless of cold rolling or hot rolling, a greater reduction increases the rolling force and strain rate, and it also produces greater residual stress and temperature rise. Further, the bulging on the sides and the crater on the end face are positively correlated with the reduction of the strip. #
A transient thermo-mechanically coupled Finite Element Method based model for single pass hot rolling of AA 5083 aluminum alloy is developed. The formulation is based on thermo-viscoplastic behavior expressed by the Perzyna constitutive equation and rolling under plane-strain conditions. The finite element model is integrated with a microstructural model where dynamic recrystal-lization through particle stimulated nucleation and static recrystallization is considered. The dynamic recrystalliza-tion model is an adoption of discontinuous dynamic recrystallization model while static recrystallization model is based on Avrami equation. The simulation results indicate that accurate estimates of constitutive behavior of the alloy, efficiency of conversion of plastic deformation to heat, and heat transfer at the roll/metal interface are critical for precise hot rolling model. Keywords Hot rolling Á AA 5083 aluminum alloy Á Finite Element Method Á Dynamic recrystallization Á Static recrystallization
Parametric Analysis of Hot Rolling Process
International Journal Of Mechanical Engineering And Information Technology, 2016
In today's scenario finite element simulation has become an important tool in the manufacturing industry. Rolling process plays an important role in manufacturing of different parts with a long range variety of dimensions. In the process of rolling, the internal raw material transform into desired shape by passing through one or more pairs of rolls. The main aim of this paper is to investigate the influence of Modelling and Simulation of different parameters such as geometry of the slab, friction between work-rolls and slab, rotational speed of work-roll, percentage of thickness reduction of slab while using rolling process. Two dimensional rolling models are used routinely in most aluminium manufacturing companies. In present research, a two dimensional elasto-plastic Finite Element model for hot rolling of a plate of aluminium has been developed to study the behavior of the paticular material under different coefficients of friction, different roller diameters and different initial thickness of the metal plate for obtaining a particular final thickness of the rolled plate. The individual effects of coefficient of friction, roller radius, and initial thickness of plate on maximum stress, strain, strain rate, equivalent plastic strain and reaction force have been obtained. The results of finite element simulation can be used to investigate the effects of parameters on mechanical properties and product integrity.
Study on Asymmetric Rolling Process Applied to Aluminum Alloy Sheets
Machines
Asymmetric rolling (ASR) is a method to manufacture sheet metals with the aim of improving material performance. The objective of the present work is to investigate the effect of asymmetric rolling on an aluminum alloy used in the automotive industry. To this end, three parameters of the process were studied, namely the asymmetry factor (1, symmetric rolling (SR) and 1.36, asymmetric rolling (AR)), the thickness reduction per pass (10%, 15%, and 30%), and the rolling routes (asymmetric continuous (ARC) and asymmetric reverse (ARR)). After rolling, the material was tested by uniaxial tensile tests to measure its strength and formability. The results show similarity between all the rolling conditions, with a considerable increase in strength and a drastic decrease in formability. In addition, a prediction of forming limit diagram using an FLD code based on Marciniak–Kuczynski analysis was used to investigate the FLD evolution with rolling. The code was capable to capture the variation...