FEM Simulation of Multipass Shape Rolling Processes

2010 ◽  
Vol 148-149 ◽  
pp. 1-6 ◽  
Author(s):  
Hai Liang Yu ◽  
Xiang Hua Liu
Keyword(s):  
Finite Element ◽  
Deformation Behavior ◽  
Fem Simulation ◽  
Element Model ◽  
Rolling Process ◽  
Pure Lead ◽  
Shape Rolling ◽  
First Pass ◽  
H Beam ◽  
Good Agreement

The updating geometric method was proposed to simulate the deformation behavior of workpiece during multipass shape rolling by using finite element method. Firstly, establish and solve the finite element model of the first pass shape rolling process, then update the geometric shape of workpiece after the first pass and delete rolls of the first pass, establish and mesh rolls of the second pass, modify the boundaries and material parameters of workpiece, and solve its deformation behavior during the second pass shape rolling. With the same steps, its deformation behavior during the following passes rolling could be solved. The method was applied to simulate the deformation behavior of a cube workpiece during six-pass H-beam rolling with split-rolling, and its shapes after every pass rolling process were obtained. Experiments on the deformation behavior of slab during multipass rolling were carried out by using pure lead in an experimental mill. The calculated results are in good agreement with the experimental ones.

Thermal Mechanical Coupled 3D Finite Element Simulation of Large H-Beam in Hot Rolling Process

2013 ◽  
Vol 281 ◽  
pp. 484-489
Author(s):  
Pei Qi Wang ◽  
Qin He Zhang ◽  
Bao Tian Dong ◽  
Ru Po Ma
Keyword(s):  
Finite Element ◽  
Rolling Force ◽  
Element Model ◽  
Rolling Process ◽  
Forming Process ◽  
Beam Production ◽  
Element Simulation ◽  
Simulation Results ◽  
Explicit Solver ◽  
H Beam

In order to research the forming process of H-beam, based on the large H-beam production line of HN600x200, the Standard and Explicit solver of ABAQUS are synthetically used to establish finite element model for rolling process and inter-pass thermolysis process. The reciprocation multi-pass rolling process simulation procedure based on the re-meshing technology is used to simulate the whole production process form blanks to finish products, and the continuity of data is ensured. Based on the simulation results, the deformation and rolling force of the roller as well as the metal flowing law and temperature field of workpiece are discussed emphatically. The results clearly show that the displacement of roller contains the elastic deformation and the deflection, and the counterforce of left adds to the counterforce of right is about equal to the resultant force. The simulation results are compared with the measuring results, which proves the correctness of simulation.

Coupled Thermo-Mechanical FEM Simulation of Multi-Pass Vertical-Horizontal Rolling Process

2014 ◽  
Vol 941-944 ◽  
pp. 1726-1734 ◽  
Author(s):  
Hong Bin Xu ◽  
Shu Rong Ding ◽  
Yong Zhong Huo
Keyword(s):  
Finite Element ◽  
Hot Rolling ◽  
Fem Simulation ◽  
Element Model ◽  
Rolling Process ◽  
Temperature Variations ◽  
Explicit Finite Element ◽  
Rate Dependent ◽  
Hot Rolling Process ◽  
Fuel Elements

The governing equations and the finite element model for the coupled thermo-mechanical multi-pass vertical-horizontal rolling process of a zircaloy strip are established. Considering the temperature-dependent and strain rate-dependent constitutive relation of zircaloy, the numerical simulation of the three-pass V-H rolling process is realized by the coupled thermo-mechanical dynamic explicit finite element method. The computational results such as the plastic deformation, the size variations and the temperature variations in three passes are discussed. The research results indicate that edging by vertical roller benefits improving the sizes of the strip and the temperature variations are rather obvious during the three-pass hot rolling process. The research provides experience and foundations for the FEM simulation of the hot rolling process of composite slabs for nuclear fuel elements.

3D Thermal Mechanical Coupled Elasto-Plastic Finite Element Analysis in the Whole Rolling Process of H-Beam

2008 ◽  
Vol 575-578 ◽  
pp. 532-538 ◽  
Author(s):  
Guo Ming Zhu ◽  
Yong Lin Kang ◽  
Wei Chen ◽  
Guang Ting Ma
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Rolling Process ◽  
Temperature Data ◽  
Measured Temperature ◽  
Element Analysis ◽  
Whole Process ◽  
Microstructure Prediction ◽  
H Beam ◽  
Good Agreement

In the H-beam rolling process, the deformations and temperature field of workpiece significantly influence the mechanical properties due to the change of product microstructure. Prediction of them is important for the groove design and passes sequences. To get the deformation behavior and the temperature field of workpiece, commercial FEM program LS-DYNA has been used to analyze the whole process of H-beam rolling. The approach is based on 3D thermal mechanical coupled finite element method. The rolling process is divided into several units for calculation. The mesh of workpiece is rebuilt in the simulation for reducing the influence of element distortion. The result shows that, the temperature at the wed to flange position maintains the highest during the whole rolling process, while area of the web the lowest. After the rolling, temperature difference is above 150K between the web’s surface and flange’s inside surface, approximate 130K on the flange’s outside surface and 200K in the cross section. The simulation results show good agreement with the measured temperature data.

Formation mechanism and prediction of plane shape in angular rolling of aluminum alloy thick plate

2018 ◽  
Vol 42 (2) ◽  
pp. 81-89
Author(s):  
Pujun Hao ◽  
Anrui He ◽  
Wenquan Sun
Keyword(s):  
Mathematical Model ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Thick Plate ◽  
Element Model ◽  
Rolling Process ◽  
Longitudinal Rolling ◽  
First Pass ◽  
Plane Shape ◽  
The Mathematical Model

A finite element model (FEM) was developed to study the plane shape of an aluminum alloy thick plate after angular rolling. Results show that the plane shape is a parallelogram after the first pass of angular rolling. When the angular rolling process is completed after a second pass, the plane shape becomes symmetric about the center lines in both length and width directions. The width increases more at the edge that enters the deformation zone earlier. Next, a mathematical model to predict plane shape after angular rolling was proposed based on a sectional calculation method. By simulating the longitudinal rolling process, spreads from different plate widths were obtained and used in the mathematical model. By comparing these results with results from the FEM, the accuracy of the mathematical model was verified. Because of its short calculation time, the mathematical model can be used in practice during the production process.

FEM Analysis of the Deformation Behavior at Thickness Direction in Laboratory Plate Hot Rolling

2014 ◽  
Vol 789 ◽  
pp. 566-573 ◽  
Author(s):  
Ji Yuan Liu ◽  
Zong An Luo ◽  
Fu Xian Zhu ◽  
Chao Tian
Keyword(s):  
Hot Rolling ◽  
Deformation Behavior ◽  
Fem Simulation ◽  
Fem Analysis ◽  
Rolling Process ◽  
Distribution Data ◽  
Thickness Direction ◽  
First Pass ◽  
Rolling Experiment ◽  
Explicit Dynamic

As significant theory evidence in thick plate or heavy gauge plate hot rolling, the deformation behavior at the thickness direction was investigated. In the present work, multi and single pass rolling processes were studied by 2D explicit dynamic finite element method (FEM) simulation and verified by laboratory hot rolling experiment. The value of stress and strain could be obtained in any passes and time in the hot rolling process accurately. The verified FEM model could be used as an important reference factor for other hot rolling processes. Strain and stress distribution data was obtained from four portions at the thickness direction. A cooper rod was knocked into the hot rolling specimen, as a reference substance to observe the deformation after the hot rolling experiment. In the multi-pass simulation with nearly 10% per-pass reduction, the core metal yield when the total reduction was 40%. The same performance could be achieved when the first pass reduction larger than 20%. However, extremely first pass reduction would cause an instability deformation result in a confusion of microstructure. Finally, the relation between the reduction and the number of rolling passes was discussed.

A Modified Finite Element Model for Electromagnetic Tube Compression Process

2012 ◽  
Vol 468-471 ◽  
pp. 456-460
Author(s):  
M. Sedighi ◽  
M. Khandaei ◽  
M.A> Liaghat
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Fem Simulation ◽  
Element Model ◽  
Experimental Results ◽  
Current Load ◽  
Compression Process ◽  
Simulation Results ◽  
Magnetic Potentials ◽  
Good Agreement

This paper presents an approach for modification a FEM simulation of electromagnetic tube compression process which has been presented by Mamalis. Electromagnetic free compression of a tube inside a coil has been simulated by using elements with coupled DOFs of electrical and magnetic potentials and displacement components. Mamalis's simulation results show a degree of disagreement with experimental results. In the present work, the coil has been modeled as separate parallel rings and a new correction factor has been determined for the current load applied on the coil. Comparison between simulation and experimental results shows a good agreement at the middle of workpiece with a reasonable error at workpiece ends.

Analysis of the Contact Deformation of Tread Blocks

1992 ◽  
Vol 20 (4) ◽  
pp. 230-253 ◽  
Author(s):  
T. Akasaka ◽  
K. Kabe ◽  
M. Koishi ◽  
M. Kuwashima
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Deformation Behavior ◽  
Contact Deformation ◽  
The Finite Element Method ◽  
The Road ◽  
Loss Of Contact ◽  
Tread Rubber ◽  
Good Agreement ◽  
Rubber Block

Abstract The deformation behavior of a tire in contact with the roadway is complicated, in particular, under the traction and braking conditions. A tread rubber block in contact with the road undergoes compression and shearing forces. These forces may cause the loss of contact at the edges of the block. Theoretical analysis based on the energy method is presented on the contact deformation of a tread rubber block subjected to compressive and shearing forces. Experimental work and numerical calculation by means of the finite element method are conducted to verify the predicted results. Good agreement is obtained among these analytical, numerical, and experimental results.

Rigid-Plastic Impact of Single Angular Particles

2021 ◽  
Author(s):  
Sandeep Dhar
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Element Model ◽  
Orientation Dependence ◽  
Particle Orientation ◽  
Rigid Plastic ◽  
Plastic Model ◽  
Model Predictions ◽  
Good Agreement ◽  
Angular Particles

The trajectory of an angular particle as it cuts a ductile target is, in general, complicated because of its dependence not only on particle shape, but also on particle orientation at the initial instant of impact. This orientation dependence has also made experimental measurement of impact parameters of single angular particles very difficult, resulting in a relatively small amount of available experimental data in the literature. The current work is focused on obtaining measurements of particle kinematics for comparison to rigid plastic model developed by Papini and Spelt. Fundamental mechanisms of material removal are identified, and measurements of rebound parameters and corresponding crater dimensions of single hardened steel particles launched against flat aluminium alloy targets are presented. Also a 2-D finite element model is developed and a dynamic analysis is performed to predict the erosion mechanism. Overall, a good agreement was found among the experimental results, rigid-plastic model predictions and finite element model predictions.

Tail Deviation Mechanism and Neural Network Control of the Tandem Rolling Strap

2011 ◽  
Vol 103 ◽  
pp. 488-492
Author(s):  
Guang Bin Wang ◽  
Xian Qiong Zhao ◽  
Yi Lun Liu
Keyword(s):  
Neural Network ◽  
Finite Element ◽  
Finite Element Model ◽  
Control Policy ◽  
Element Model ◽  
Rolling Process ◽  
Network Control ◽  
Neural Network Control ◽  
The Neural Network ◽  
The Finite Element Model

In the rolling process, deviation is the phenomenon that the strap width direction's centerline deviates from rolling system setting centerline,serious deviation will cause product quality drop and rolling equipment fault. This paper has established the finite element model to the hot tandem rolling aluminum strap, analyzed the strap’s deviation rule under four kinds of incentives,obtained the neural network predictive model and the control policy of the tail deviation.The result to analyze a set of fact deviation data shows this method may control tail deviation in preconcerted permission range.

FEM Simulation of Anisotropic Parameters Influencing the Earing in Sheet Metal Deep Drawing Process

2011 ◽  
Vol 88-89 ◽  
pp. 638-641 ◽  
Author(s):  
Lei Chen
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Sheet Metal ◽  
Deep Drawing ◽  
Fem Simulation ◽  
Element Model ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Material Characteristics

Earing is often undesirable in the production of deep drawn containers because it results in a nonuniform cup height. A finite element model for earring analysis is developed considering only the flange area of the sheet. It was found that the draw-in depth of the flange increases with the increase of the r value, and it remains invariable when r value is larger than 2. With the increase of the r value, the max thickness decreases and the min thickness increases. If △r>0, four earings are formed. If △r =0, the material characteristics in all the planar directions are same. The flange uniformly flows into the die cavity, no earing is formed. If △r<0, four earings are formed. The earing distribution is dominated by r0, r45 and r90. Both r and △r have much effect on the earing distribution.

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