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Modeling of mass flow behavior of hot rolled low alloy steel based on combined Johnson-Cook and Zerilli-Armstrong model

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Abstract

Accuracy and reliability of numerical simulation of hot rolling processes are dependent on a suitable material model, which describes metal flow behavior. In the present study, Gleeble hot compression tests were carried out at high temperatures up to 1300 °C and varying strain rates for a medium carbon micro-alloyed steel. Based on experimental results, a Johnson-Cook model (JC) and a Zerilli-Armstrong (ZA) model were developed and exhibited limitation in characterizing complex viscoplastic behavior. A combined JC and ZA model was introduced and calibrated through investigation of strain hardening, and the coupled effect of temperature and strain rate. Results showed that the combined JC and ZA model demonstrated better agreement with experimental data. An explicit subroutine of the proposed material model was coded and implemented into a finite element model simulating the industrial hot rolling. The simulated rolling torque was in good agreement with experimental data. Plastic strain and stress distributions were recorded to investigate nonlinear mass flow behavior of the steel bar. Results showed that the maximum equivalent plastic strain occurred at 45° and 135° areas of the cross section. Stress increased with decreasing temperature, and the corresponding rolling torque was also increased. Due to the extent of plastic deformation, rolling speed had limited influence on the internal stress of the bar, but the relative rolling torque was increased due to strain rate hardening.

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Acknowledgements

This work was supported by the Peaslee Steel Manufacturing Research Center at Missouri University of Science and Technology. The authors would like to thank Geary W. Ridenour from Gerdau—Fort Smith for technical input, and also Rafael Pizarro Sanz from Gerdau—Spain for Gleeble testing.

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Authors and Affiliations

  1. Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Rolla, MO, 65409, USA

    X. Wang & K. Chandrashekhara

  2. Department of Materials Science and Engineering, Missouri University of Science and Technology, Rolla, MO, 65409, USA

    S. A. Rummel, S. Lekakh, D. C. Van Aken & R. J. O’Malley

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  1. X. Wang
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  2. K. Chandrashekhara
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  3. S. A. Rummel
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  4. S. Lekakh
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  5. D. C. Van Aken
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  6. R. J. O’Malley
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Correspondence to K. Chandrashekhara.

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Wang, X., Chandrashekhara, K., Rummel, S.A. et al. Modeling of mass flow behavior of hot rolled low alloy steel based on combined Johnson-Cook and Zerilli-Armstrong model. J Mater Sci 52, 2800–2815 (2017). https://doi.org/10.1007/s10853-016-0570-8

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  • DOI: https://doi.org/10.1007/s10853-016-0570-8

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