Application of 3D FEM-slab method to shape rolling

Hsiang, Su-Hai; Lin, Sheng-Li

doi:10.1016/s0020-7403(00)00064-3

Cited by 21 publications

(9 citation statements)

References 14 publications

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“…For a rolling process, the contact response is complex because the blank is an elastic-plastic part, and the roller is an elastic part if ignoring the small plastic deformation. The slab method is essential way for analyzing the contact and deformation of rolling process [13][14][15]. It is generally believed that the rolling bite, that is, the rolling contact area, can be divided into the forward slip zone and backward slip zone, as illustrated in Figure 1.…”

Section: Introductionmentioning

confidence: 99%

A Numerical Study on Contact Condition and Wear of Roller in Cold Rolling

Jin

Wang

Jiang

et al. 2017

Metals

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An accurate determination of the contact pressure and local sliding in a cold rolling process is an essential step towards the prediction of the roller's life due to wear damage. This investigation utilized finite element analysis to quantify the local contact pressure and local sliding over the rolling bite in a plate cold rolling process. It was the first study to quantify the local sliding distance in a rolling process using the Finite Element Analysis (FEA). The numerical results indicate that the local contact pressure over the rolling bite demonstrates a hill profile, and the peak coincides with the neutral plane. The local sliding distance over the rolling bite demonstrates a double-peak profile with the two peaks appearing at the forward slip and backward slip zones respectively. The amplitude of sliding distance in the backward slip zone is larger than that in the forward slip zone. A stick zone was confirmed between the forward slip and backward slip zones. According to a parametric study, the local contact pressure and sliding distance decrease when the thickness reduction is reduced or the diameter of the roller is decreased. The location of the neutral plane always presents at the rolling exit side of the rolling bite's center. The size of the stick zone enlarges and the sizes of slip zones shrink significantly when the friction coefficient is increased. Finally, a novel concept of wear intensity was defined to examine the wear of the roller based on the local contact pressure and local sliding distance. The results show that a two-peak wear response exists in the backward and forward slip zones. The magnitude of the wear in the backward slip zone is larger than that in the forward slip zone. For a given roller and blank material combination, using a smaller thickness reduction, a smaller diameter roller and a higher friction coefficient condition can reduce the wear of the roller for a single rolling cycle. The current paper develops an understanding of rolling contact responses to the wear of the roller in rolling process. The research method can also be applied to study other rolling or sliding wear problems.

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Section: Introductionmentioning

confidence: 99%

A Numerical Study on Contact Condition and Wear of Roller in Cold Rolling

Jin

Wang

Jiang

et al. 2017

Metals

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“…4 Park and Oh 5 wrote a FE code suitable for analyzing of material flow in shape rolling in simple geometries such as circle and square. The first investigation using the FE analysis in caliber design was carried out by Lapovok and Thomson 6 and a few years after, lots of researches have been carried out in the field of caliber design 5–8 to simulate the rolling process and to save CPU time. They mostly found the metal forming parameters such as forming pressures and stresses, necessary energies, and velocity of slab by the FEM.…”

Section: Introductionmentioning

confidence: 99%

New multi-pass hot channel section rolling design by the finite element method

Sakhaei

Salimi

Kadkhodaei

2013

Proceedings of the Institution of Mechanical Engineers, Part C:

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A new multi-pass hot shape rolling was designed based on a three-dimensional analysis of channel section beams in hot rolling by the finite element method. A complete production line in industry containing 13 passes in forming the section including break-down, intermediate, and finishing sequences is modeled. The output geometry and power consumption predicted by this simulation were verified against the practical data and the measured values of the production line of Zobahan Esfahan Company. Then, a sample caliber design process to achieve a specific cross section is prepared. The minimum possible number of passes consistent with the parameters affecting the spread is the main strategy of the new caliber design. Again this new caliber design is simulated using an explicit finite element code. The geometry and dimensions of the exit cross section, the separation force, roll torques, and the power consumption in each stage are calculated. Comparison of the new roll pass parameters and that of the conventional ones in industry is made to demonstrate the advantages of the new caliber design.

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“…Bayoumi (1998) used a flow-line field solution to analyze material flow and stresses in the steady-state rolling of a round-oval-round sequence. Hsiang and Lin (2001) developed a piecewise complex model combining the slab and finite element methods. They divided the deformation zone into several slabs and used FEM to calculate sequentially the velocity field, metal flow, stress and strain distribution for each slab.…”

Section: Introductionmentioning

confidence: 99%

Three-dimensional analysis of shape rolling using a generalized upper bound approach

Abrinia

Fazlirad²

2009

Journal of Materials Processing Technology

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Shape rollingUpper bound Roll pass Velocity field Shaped sections a b s t r a c t A generalized analytical method has been proposed to study external shape and calculate pressure and torque for the process of rolling shaped sections. The proposed method is based on the upper bound analysis. To determine kinematically admissible velocity fields, flow lines have been mathematically formulated using the parameterization of curves. Based on the calculated velocity fields, an upper bound has been found on rolling power. The calculated power has been minimized with respect to unknown variables to yield the value closest to the actual power required.The proposed general method has been applied to certain rolling passes including squareto-oval and round-to-oval. Velocity fields and power relations have been obtained for each process. Computer analysis has been carried out for all the mentioned passes using dimensions and conditions from experiments conducted by other workers. External shape, average roll torque and average rolling pressure results from the analysis have been compared with analytical solutions, numerical analyses and experimental data presented by other workers.It was concluded that the present method gave very good results and was quicker and easier to use.

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Application of 3D FEM-slab method to shape rolling

Cited by 21 publications

References 14 publications

A Numerical Study on Contact Condition and Wear of Roller in Cold Rolling

A Numerical Study on Contact Condition and Wear of Roller in Cold Rolling

New multi-pass hot channel section rolling design by the finite element method

Three-dimensional analysis of shape rolling using a generalized upper bound approach

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