In aluminum foil rolling, the secondary particles may lead to stress concentration at the boundary between these particles and the matrix. Different types of particles would result in stress concentration at different levels. The three dimensional finite element modeling (3D-FEM) was used to simulate the effect of the particles with different hardness on mechanical properties of the matrix of AA1235 aluminum foils in its foil rolling process. The hardness ratio was used to evaluate the mechanical property of foils. It has been found that when the hardness ratio of the particle was similar to that of the matrix (R=1), the interaction mechanism of the dislocations with the particle was dislocation cutting way. When the hardness ratio of the particle to the matrix increased from 1 to 6, the interaction mechanism of the particle with the matrix changed from the dislocation cutting way to the Orowan dislocation bypass way. When the hardness ratio increased to as high as 6, dislocation interacted with the particle only by the Orowan dislocation bypass way.
