Skip to main content
SpringerLink
Log in

Heat transfer in cold rolling process of AA8015 alloy: a case study of 2-D FE simulation of coupled thermo-mechanical modeling

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The finite element method (FEM) is one of the most applicable mathematical analytic methods of rolling processes and is also an efficient method for analyzing coupled heat transfer. Thermal analysis of cold rolling process is not frequently used due to the widespread assumption of insignificant impact during rolling process. This research focuses on the development of coupled thermo-mechanical 2-D FE model analysis approach to study the thermal influence and varying coefficient of friction during the industrial cold rolling process of AA8015 aluminum alloy. Both deformable-rigid and deformable-deformable rigid contact algorithms were examined in the 2-D FE model. Findings revealed that temperature distribution in the roll bite rises steadily in a stepwise manner. The deformable-deformable contact algorithm is the best investigations of thermal behavior of the rolled metal and work rolls necessary for typical application in work roll design. The predicted roll separating force is validated with industrial measurements.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Lenard JG (2007) Primer on flat rolling, 1st edn. Elsevier Science

  2. Singh RV (2011) Aluminium rolling: processes, principles & applications. McGraw-Hill Education, New Delhi

    Google Scholar 

  3. Stephenson DA (1983) Lubrication in cold strip rolling. Wear 92(2):293–311

    Article  Google Scholar 

  4. Keife H, Sjogren C (1994) A friction model applied in the cold rolling of aluminum strips. Wear 179:137–142

    Article  Google Scholar 

  5. Lenard JG, Zhang S (1997) A study of frction during the lubricated cold rolling of an aluminium alloy. J Mater Process Technol 72:293–301

    Article  Google Scholar 

  6. McConnell C, Lenard JG (2000) Friction in cold rolling of a low carbon steel with lubricants. J Mater Process Technol 99:86–93

    Article  Google Scholar 

  7. Jiang ZY, Xiong SW, Tieu AK, Wang QJ (2008) Modelling of the effect of friction on cold strip rolling. J Mater Process Technol 201:85–90

    Article  Google Scholar 

  8. Wilson WRD, Chang CT, Sa CY (1989) Interface temperatures in cold rolling. J Mater Shap Technol 6:229–240

    Article  Google Scholar 

  9. Galantucci LM, Tricarico L (1999) Thermo-mechanical simulation of a rolling process with an FEM approach. J Mater Process Technol 92-93:494–501

    Article  Google Scholar 

  10. Louaisil K, Dubar M, Deltombe R, Dubois A, Dubar L (2008) Simulation of interface temperature and control of lubrication in the study of friction and wear in cold rolling. Int J Mater Form 1(1239):1242

    Google Scholar 

  11. Azushima A (2016) Tribology in sheet rolling technology. Springer International Publishing, Switzerland

    Book  Google Scholar 

  12. Liu YJ, Tieu AK, Wang DD, Yuen WYD (2001) Friction measurement in cold rolling. J Mater Process Technol 111:142–145

    Article  Google Scholar 

  13. Shaw MC, Ber A, Mamin PA (1960) Friction characteristics of sliding surfaces undergoingsubsurface plastic flow. J Basic Eng 82(2):342–345

    Article  Google Scholar 

  14. Banerji A, Rice WB (1972) Experimental determination of normal pressure and friction stress in the rolling gap during cold rolling. Annals of the CIRP 21:53–54

    Google Scholar 

  15. Al-Salehi FAR, Firbank TC, Lancaster PB (1973) An experimental determination of the roll pressure distribution in cold rolling. Int J Mech Sci 15:693–710

    Article  Google Scholar 

  16. Nyahumwa C, Jeswiet J (1991) A friction sensor for sheet-metal rolling. CIRP Annals- Manufacturing Technology 40(1):231–233

    Article  Google Scholar 

  17. Jeswiet J (1993) A sensor for measuring metal deformation interface forces. J Mater Process Technol 39(3–4):251–268

    Article  Google Scholar 

  18. Azushima A, Kudo H (1995) Direct observation of contact behaviour to interpret the pressure dependence of the coefficient of friction in sheet metal forming. CIRP Annals- Manufacturing Technology 44(1):209–212

    Article  Google Scholar 

  19. Tieu AK, Liu YJ (2004) Friction variation in the cold-rolling process. Tribol Int 37:177–183

    Article  Google Scholar 

  20. Jiang ZY, Tieu AK, Zhang XM (2004) Finite element modelling of mixed film lubrication in cold strip rolling. J Mater Process Technol 151(1–3):242–247

    Article  Google Scholar 

  21. Liu QY, Jin XS, Zhou ZR (2005) An investigation of friction characteristic of steels under rolling -sliding condition. Wear 259(1–6):439–444

    Article  Google Scholar 

  22. Ghosh MK, Majumdar BC, Sarangi M (2014) Fundamentals of fluid film lubrication. McGraw-Hill Education, New Delhi

    Google Scholar 

  23. ASTM Standards: E8/E8M-15a. Standard test methods for tension testing of metallic materials

  24. Knitel S, Spatig P, Seifert HP (2016) An inverse method based on finite element model to derive the plastic flow properties from non-standard tensile specimens of Eurofer97 steel. Nucl Mater Energy 9:311–316

    Article  Google Scholar 

  25. Prihod’ko I, Krot P, Solov’yov K, Parsenyuk E, Chernov P, Pimenov V et al (2006) Vibration monitoring system and the new methods of chatter early diagnostics for tandem mill control. Proceedings of international conference London, United Kingdom, p 87–106

  26. Montmitonnet P (2006) Hot and cold strip rolling process. Comput Methods Appl Mech Eng 195(48–49):6604–6625

    Article  MATH  Google Scholar 

  27. Madhusudana CV (2014) Thermal contact conductance, 2nd edn. Springer International Publishing, Switzerland

    Book  Google Scholar 

  28. Timothy SP, Yiu HL, Fine JM, Ricks RA (1991) Simulation of single pass of hot rolling deformation of aluminium alloy by plane strain compression. J Mater Sci Technol 7(3):195–201

    Article  Google Scholar 

  29. Pietrzyk M, Lenard JG (1989) A study of thermal-mechanical modeling of hot flat rolling. Journals of Materials Shaping Technology 7(2):117–126

    Article  Google Scholar 

  30. Lienhard JH IV, Lienhard V, J. H. (2003) A heat transfer textbook, 3rd edn. Phlogiston Press, Cambridge

    MATH  Google Scholar 

  31. Agilent Technologies (2007) Material expansion coefficients. Agilent laser and optics: User’s manual, volume I. Agilent Technologies Inc., California, pp 280–290 http://www.uzimex.cz/soubory/20080403_laser_optika_cast_1.pdf

    Google Scholar 

  32. Efunda (2017) Thermal conductivity: Aluminum. Retrieved 7/15, 2017, from http://www.efunda.com/materials/elements/TC_Table.cfm?Element_ID=Al

  33. Kaye&Label (2017) Thermal conductivities. Retrieved 7/15, 2017, from http://www.kayelaby.npl.co.uk/general_physics/2_3/2_3_7.html

Download references

Acknowledgements

The authors want to thank the University of Johannesburg and the Council for Scientific and Industrial Research (CSIR) South Africa for their support of this research. The authors would also like to express gratitude toward Tower Aluminum, Nigeria, for their contribution in providing the aluminum samples and data collection. Special thanks to the factory manager for his hospitality. The finite element simulations were performed on assets provided by Lulea University of Technology, Sweden.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering Science, University of Johannesburg, Johannesburg, South Africa

    O. Olaogun & E. T. Akinlabi

  2. Department of Mechanical Engineering, Kwara State University, Malete, Nigeria

    O. Olaogun

  3. Department of Engineering Sciences & Mathematics, Luleå University of Technology, Luleå, Sweden

    J. Edberg & L.-E. Lindgren

  4. Department of Mechanical Engineering, University of Ibadan, Ibadan, Nigeria

    O. O. Oluwole

Authors
  1. O. Olaogun
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. J. Edberg
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. L.-E. Lindgren
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. O. O. Oluwole
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. E. T. Akinlabi
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to O. Olaogun.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Olaogun, O., Edberg, J., Lindgren, LE. et al. Heat transfer in cold rolling process of AA8015 alloy: a case study of 2-D FE simulation of coupled thermo-mechanical modeling. Int J Adv Manuf Technol 100, 2617–2627 (2019). https://doi.org/10.1007/s00170-018-2811-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-2811-2

Keywords

Search

Navigation