Numerical Analysis of Edge Cracking in High-Silicon Steel during Cold Rolling with 3D Fracture Locus

In this study, a 3D fracture locus of high-silicon steel strip was constructed through a series of fracture tests with specimens of various shapes and corresponding finite element (FE) simulations of the fracture tests. A series of FE analyses coupled with the developed fracture locus was conducted, and the effect of the secondary roll-bending ratio (defined as L2/R2, where L2 and R2, respectively, denote the secondary work roll barrel length and the radius of the convex curvature of the work roll surface profile emulating positive roll bending) and the initial notch length on edge cracking in the strip during cold rolling was investigated. The results reveal that the 2D fracture locus that does not include the Lode angle parameter (varying between −0.81 and 0.72 during cold rolling) overestimates the edge cracking in the range of 13.1–22.2%. The effect of the initial notch length on the length of crack grown in the transverse direction of the strip during cold rolling is greatest when the ratio L2/R2 is 0.12.

Initiation and Suppression of Crack Propagation during Magnesium Alloy Rolling

The conventional rolling of magnesium alloy with a single pass and large reduction will cause severe edge cracking. The sheet without cracks can be achieved by limited width rolling. The microstructure evolution of the sheet with cracks after conventional rolling and the sheet without cracks after limited width rolling is explored, and an effective mechanism for solving edge cracks is proposed. Conventional rolling can fully develop twin evolution due to high deformation, and three stages of twinning evolution can be observed and the secondary twins easily become the nucleation points of micro cracks, resulting in a large number of cracks propagating along the twin lamellae. Cracks terminate at dislocation accumulation because the accumulation of a large number of dislocations can hinder propagation. Dislocation shearing of twins to eliminate the high localization caused by twins and induce the tensile twins to weaken the basal surface texture provides an effective plastic deformation mechanism of crack inhibition, which is useful for expanding the engineering application of magnesium alloy rolled sheets.

Deformation and Damage Assessments of Two DP1000 Steels Using a Micromechanical Modelling Method

Damage characterization and micromechanical modelling in dual-phase (DP) steels have recently drawn attention, since any changes in the alloying elements or process route strongly influence the microstructural features, deformation behavior of the phases, and damage to the micro-mechanisms, and subsequently the particular mechanical properties of the material. This approach can be used to stablish microstructure–properties relationships. For instance, the effects of local damage from shear cutting on edge crack sensitivity in the following deformation process can be studied. This work evaluated the deformation and damage behaviors of two DP1000 steels using a microstructure-based approach to estimate the edge cracking resistance. Phase fraction, grain size, phase distribution, and texture were analyzed using electron backscatter diffraction and secondary electron detectors of a scanning electron microscope and employed in 3D representative volume elements. The deformation behavior of the ferrite phase was defined using a crystal plasticity model, which was calibrated through nanoindentation tests. Various loading conditions, including uniaxial tension, equi-biaxial tension, plane strain tension, and shearing, along with the maximum shear stress criterion were applied to investigate the damage initiation and describe the edge cracking sensitivity of the studied steels. The results revealed that a homogenous microstructure leads to homogenous stress–strain partitioning, delayed damage initiation, and high edge cracking resistance.