A coupled finite element method for a three-dimensional analysis of the flat rolling of aluminum with different reductions

In this paper, the authors have developed a finite element model to establi sh a heat transfer finite element model and a three-dimensional large defor mation thermo elastic-plastic finite element model, which is then coupled t o form a complete theoretical model including heat transfer. In this theore tical model, the two variables of element deformation and temperature varia tion 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 mod el of metal rolling formation is developed from the theoretical model. The numerical simulation model developed in this paper was used to simulate alu minum strip rolling. Simulation of the rolling process of aluminum strips i n cold rolling and hot rolling under different reductions of the strip were conducted to obtain the effects of: different reductions of the strip on r olling, and obtain related reference date for the practical rolling process . The simulation results were compared with experimental values to verify t he feasibility of the theoretical model and numerical simulation model esta blished in this study. The simulation presented in this paper indicates tha t regardless of cold rolling or hot rolling, a greater reduction increases the rolling force and strain rate, and it also produces greater residual st ress 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. (C) 2001 Elsevier Science B.V. All rights reserved.