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Mathematical Modeling of Multipass Hot Deformation of Aluminum Alloy AA5083—Model Development and Validation

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Hot rolling, a critical step in the manufacturing of sheet products, influences the final sheet properties based on the microstructure evolution during this operation. A comprehensive mathematical model of the hot rolling process for aluminum alloys has been developed. This article outlines the development of a two-dimensional (2-D) mathematical model to simulate multipass hot rolling using the commercial finite element (FE) package, ABAQUS. Microstructure evolution during multipass rolling was modeled using a physically based approach to predict the stored energy and the resulting microstructure for an AA5083 aluminum alloy. The stored energy in the material between passes is quantified using a rule-of-mixtures approach based on the fraction of the material that is recrystallized. An extensive experimental program was undertaken to validate the model using Corus’ single-stand reversible rolling facility located in IJmuiden, The Netherlands. Overall, the model was able to simulate the thermomechanical history experienced during multipass hot rolling reasonably well based on comparison to temperature and rolling load measurements. The model was also able to predict the fraction recrystallized through the thickness of the strip reasonably well, but the grain size predictions were consistently low.

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Notes

  1. ABAQUS is a trademark of ABAQUS, Inc., Providence, RI, USA.

Abbreviations

d 0 :

initial grain size, μm

d rex :

recrystallized grain size, μm

t :

time, s

\( \ifmmode\expandafter\dot\else\expandafter\.\fi{N} \) :

nucleation rate

\( \ifmmode\expandafter\dot\else\expandafter\.\fi{G} \) :

growth rate

Q :

activation energy, J mole−1

n :

Avrami exponent

T :

temperature °C, K

X :

position along the length of the strip, mm

Y :

position through the thickness of the strip, mm

X v :

fraction transformed, pct

ε :

strain

\( \ifmmode\expandafter\dot\else\expandafter\.\fi{\varepsilon } \) :

strain rate, s−1

R:

universal gas constant, J mole−1 °C−1

σ f :

frictional stress, Pa

ρ r :

random dislocation density, m−2

ρ g :

geometrical necessary dislocation density, m−2

ρ ι :

internal dislocation density, m−2

μ :

coefficient of friction

τ :

shear stress, Pa

G :

shear modulus, Pa

W :

temperature compensated time parameter, s

δ :

average subgrain size, m

θ :

average misorientation angle between subgrains, deg

B :

burgers vector, m

N v :

nucleation density, m−3

N PSN :

particle-stimulated nucleation, m−3

N C :

cube nucleation, m−3

N GB :

grain boundary nucleation, m−3

P D :

driving force, Pa

S V :

grain boundary area per unit volume, μm−1

δt :

time increment, s

δε :

strain increment

dθ :

misorientation angle between subgrains increment, deg

dδ :

average subgrain size increment, μm

dρ r :

random dislocation density increment, m−2

d 1 :

grain length in the y direction, μm

d 2 :

grain width in the x direction, μm

Z :

Zener–Hollomon parameter, s−1

Subscripts and superscripts :

 

def:

deformation

deformed:

deformed

rex:

recrystallization

roll:

roll

entry:

entry

strip:

strip

interpass:

interpass

ss :

steady state

eff:

effective

i :

current pass

i–1:

previous pass

r :

random

G :

geometrical necessary

C :

critical

a :

annealing

0:

starting

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Acknowledgments

The authors are grateful to Corus for funding this research project as well as providing access to their experimental rolling mill. The useful discussions with Drs. C. Liu and A. Norman and the technical help of Messrs. J. Wörmann and J. Brussel, Corus RD&T, are gratefully acknowledged. The financial support of the Natural Sciences and Engineering Research Council of Canada (NSERC) in the form of a graduate scholarship is gratefully acknowledged.

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Author notes

  1. H. Ahmed (Post Doctoral Researcher)

    Present address: Netherlands Institute of Metals Research (NIMR), TU Delft, Delft, The Netherlands

Authors and Affiliations

  1. University of British Columbia, Vancouver, BC, Canada, V6T 1Z4

    H. Ahmed (Post Doctoral Researcher)

  2. Advanced Materials & Process Engineering Laboratory, University of British Columbia, Vancouver, BC, Canada, V6T 1Z4

    M.A. Wells (Associate Professor and Alcan chair in materials process engineering), D.M. Maijer (Assistant Professor) & G. Lockhart (Research Engineer)

  3. Corus RD&T, IJmuiden Technical Centre, 1970, CA, IJmuiden, The Netherlands

    M.R. Van der Winden (Department Manager)

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  1. H. Ahmed
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  2. M.A. Wells
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  5. M.R. Van der Winden
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Corresponding author

Correspondence to H. Ahmed.

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Manuscript submitted October 11, 2005.

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Ahmed, H., Wells, M., Maijer, D. et al. Mathematical Modeling of Multipass Hot Deformation of Aluminum Alloy AA5083—Model Development and Validation. Metall Mater Trans A 38, 922–935 (2007). https://doi.org/10.1007/s11661-007-9101-1

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