Abstract
The finite element (FE) method is a powerful tool for simulating industrial metal forming processes such as metal rolling. FE allows users to estimate the stress distribution in the metal sheet during the rolling process. However, FE simulations do not allow for real-time online process control due to model complexity and computational time. This paper forms part of a large-scale research project aimed at designing a simple-but-accurate mathematical model that provides sufficiently precise results (compared to FE simulations) with faster computational timescales allowing for real-time process control. To validate the asympotics-based mathematical model, an accurate FE model is required. In this paper, we give a detailed description of a quasi-static Abaqus/Explicit FE model and show how this is optimised to represent the rolling process. We report new insights gained from the FE simulations which can guide the development of simpler, faster mathematical models.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Allwood, J.M., et al.: Sustainable Materials: with Both Eyes Open, vol. 2012. UIT Cambridge Limited, Cambridge (2012)
Cawthorn, C., Minton, J., Brambley, E.: Asymptotic analysis of cold sandwich rolling. Int. J. Mech. Sci. 106, 184–193 (2016)
Dassault Systémes: SIMULIA User Assistance 2020 Abaqus (2020)
Edberg, J., Lindgren, L.E.: Efficient three-dimensional model of rolling using an explicit finite-element formulation. Commun. Numer. Methods Eng. 9(7), 613–627 (1993)
Erfanian, M., Brambley, E., Flanagan, F., O’Kiely, D., O’Connor, A.: New models for cold rolling: generalized slab theory and slip lines for fast predictions without finite elements (2023)
Gavalas, E., Pressas, I., Papaefthymiou, S.: Mesh sensitivity analysis on implicit and explicit method for rolling simulation. Int. J. Struct. Integrity 9(4), 465–474 (2018)
Ktari, A., Antar, Z., Haddar, N., Elleuch, K.: Modeling and computation of the three-roller bending process of steel sheets. J. Mech. Sci. Technol. 26, 123–128 (2012)
Lenggana, B.W., et al.: Effects of mechanical vibration on designed steel-based plate geometries: behavioral estimation subjected to applied material classes using finite-element method. Curved Layered Struct. 8(1), 225–240 (2021)
Lindgren, L.E., Edberg, J.: Explicit versus implicit finite element formulation in simulation of rolling. J. Mater. Process. Technol. 24, 85–94 (1990)
Mang, T., et al.: Encyclopedia of Lubricants and Lubrication, vol. 1. Springer, Heidelberg (2014). https://doi.org/10.1007/978-3-642-22647-2
Min, W., He, Y., Sun, Z.C., Guo, L.G., Ou, X.Z.: Dynamic explicit FE modeling of hot ring rolling process. Trans. Nonferrous Met. Soc. China 16(6), 1274–1280 (2006)
Minton, J.J.: Mathematical modelling of asymmetrical metal rolling processes. Ph.D. thesis, University of Cambridge (2017)
Minton, J., Cawthorn, C., Brambley, E.: Asymptotic analysis of asymmetric thin sheet rolling. Int. J. Mech. Sci. 113, 36–48 (2016)
Natário, P., Silvestre, N., Camotim, D.: Web crippling failure using quasi-static FE models. Thin-Walled Struct. 84, 34–49 (2014)
Prior, A.: Applications of implicit and explicit finite element techniques to metal forming. J. Mater. Process. Technol. 45(1–4), 649–656 (1994)
Qian, X., Chengguo, W., Ge, G.: The research of parallel computing for large-scale finite element model of wheel/rail rolling contact. In: 2010 3rd International Conference on Computer Science and Information Technology, vol. 1, pp. 254–257. IEEE (2010)
Ray, S.: Principles and Applications of Metal Rolling. Cambridge University Press, Cambridge (2016)
Richelsen, A.B.: Comparison of a numerical analysis of rolling with experimental data. J. Mater. Process. Technol. 57(1–2), 70–78 (1996)
Smet, R.P., Johnson, R.E.: An asymptotic analysis of cold sheet rolling. J. Appl. Mech. 56, 33–39 (1989)
Tapponnier, P., Molnar, P.: Slip-line field theory and large-scale continental tectonics. Nature 264(5584), 319–324 (1976)
Acknowledgements
This publication has emanated from research conducted with the financial support of Science Foundation Ireland under Grant number 18/CRT/6049. For the purpose of Open Access, the author has applied a CC BY public copyright licence to any Author Accepted Manuscript version arising from this submission.
Dr O’Connor is funded by the European Union through the Marie Skłowodska-Curie Actions grant number 101028291. Mozhdeh Erfanian gratefully acknowledges the funding of a University of Warwick Chancellor’s Scholarship. Edward James Brambley is grateful for the UKRI Future Leaders’ Fellowship funding (MR/V02261X/1) supporting this work.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2024 The Author(s), under exclusive license to Springer Nature Switzerland AG
About this paper
Cite this paper
Flanagan, F., O’Kiely, D., O’Connor, A., Erfanian, M., Brambley, E.J. (2024). New Discoveries in Cold Rolling: Understanding Stress Distribution and Parameter Dependence for Faster, More Accurate Models. In: Mocellin, K., Bouchard, PO., Bigot, R., Balan, T. (eds) Proceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity. ICTP 2023. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-031-41023-9_22
Download citation
DOI: https://doi.org/10.1007/978-3-031-41023-9_22
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-031-41022-2
Online ISBN: 978-3-031-41023-9
eBook Packages: EngineeringEngineering (R0)