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Analysis of Bonding Behavior and Critical Reduction of Two-Layer Strips in Clad Cold Rolling Process

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Abstract

In recent years, two-layer metallic sheets have been increasingly used in various industries to create combined functions. Among cladding methods, the cold rolling is most widely used in producing bimetallic sheets. In this research, to thoroughly provide guidelines for cold rolling of bimetal strip, an attempt has been made to develop an analytical model based on upper bound method. Also, the bonding strength and critical reduction were calculated using upper bound theorem and the finite element simulation was used for Al/St bimetallic strip. Finally, an experimental study was run for our model to be verified analytically and numerically. Results show that the bonding strength of strips increases with increasing the total thickness reduction of bimetal strips and because of subsequent occurrence of strips bonding in roll gap, increasing the yield strength of base layer gives rise to critical reduction. Through the study, it becomes clear that the proposed analytical model is applicable for simulating the cold rolling process of the two-layer strips and is capable to broaden our knowledge in manufacturing and production of bimetal strips and sheets.

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Abbreviations

t i, mm:

Initial thickness of bimetal strips

t f, mm:

Final thickness of bimetal strips

t 0, mm:

Initial thickness of composite

t s0, mm:

Initial thickness of clad layer

t h0, mm:

Initial thickness of base layer

t sf, mm:

Final thickness of clad layer

t hf, mm:

Final thickness of base layer

V 01, mm/s:

Initial velocity of clad layer

V 02, mm/s:

Initial velocity of base layer

V f, mm/s:

Final velocity of bimetal strip

V, mm/s:

Linear velocity of roll

\( V^{\prime}_{01} ,V^{\prime}_{02} \), mm/s:

Linear velocity in (V) and (VI) regions

ωR, 1/s:

Rotational velocity of roll

ωi, 1/s:

Rotational velocity of each rigid zone

n :

Strain hardening exponent

Γi :

Surface of velocity discontinuity

R 0, mm:

Radius of roll

R i, mm:

Radius of cylindrical surface of velocity discontinuity

ξi and λi :

Velocity ratio in the rigid zones

ΔV i, mm/s:

Amount of velocity discontinuity on each surface of velocity discontinuity

W i :

Shear power of the surface of velocity discontinuity

J*:

Total shear power

m 1 :

Friction factor between roll and strips

m 2 :

Constant friction factor between layers

σ0S, MPa:

Yield stress of clad layer (outer layer)

σ0h, MPa:

Yield stress of base layer (inner layer)

Τ, MPa:

Shear stress

K′, MPa:

Bonding strength between two layers

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Acknowledgments

The authors would like to thank the Research Board of Shahid Rajaei University, Lavizan, Tehran, Iran, for the equipment support and provision of the research facilities used in this work. Also, the help by Eng. Amir Bagherzadeh is acknowledged.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Amirkabir University of Technology, 424 Hafez Avenue, P.O. Box 4413-15875, Tehran, Iran

    H. Maleki & B. Mollaei-Dariani

  2. Department of Mechanical Engineering, College of Engineering, University of Tehran, Tehran, Iran

    S. Bagherzadeh & K. Abrinia

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  1. H. Maleki
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  2. S. Bagherzadeh
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  3. B. Mollaei-Dariani
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  4. K. Abrinia
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Correspondence to H. Maleki.

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Maleki, H., Bagherzadeh, S., Mollaei-Dariani, B. et al. Analysis of Bonding Behavior and Critical Reduction of Two-Layer Strips in Clad Cold Rolling Process. J. of Materi Eng and Perform 22, 917–925 (2013). https://doi.org/10.1007/s11665-012-0342-9

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  • DOI: https://doi.org/10.1007/s11665-012-0342-9

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