A simulation of three-dimensional metal rolling processes by rigid-plasticfinite element method

Using different frictional shear stress models, mesh division and number of elements in the deformation zone, this paper focuses on analysing the infl uence of friction variation on the convergence and results of simulation su ch as rolling pressure, forward slip and spread by 3D rigid-plastic FEM. Th e effects of mesh division and the number of elements on the precision, sta bility and convergence of the simulation are also discussed. This investiga tion shows that the frictional shear stress model with a variation in the d eformation zone can provide satisfactory results that are in good agreement with experimental values, and are also more accurate than results from oth er methods. Suitable mesh division can improve the precision and effectiven ess of the simulation. The results of the simulation are discussed for fron t and back tensions. (C) 2001 Elsevier Science B.V. All rights reserved.