Residual stresses induced in cold rolling process by using FINITE Element Analysis

Z.Y. Jiang a,, A.K. Tieu a, X.M. Zhang b, C. Lua, W.H. Suna
Faculty of Engineering, University of Wollongong, Northfields Avenue, Wollongong, NSW 2522, Australia b State Key Laboratory of Rolling Technology and Automation, Northeastern University, Shenyang, Liaoning 110004, PR China

Abstract In this work, the authors use a full 3D rigid plastic finite element method (FEM) to simulate the thin strip rolling taking into account the modelling of friction variation in the roll bite. A comparison of the computed results with measured values was conducted. The characteristics of the distribution of the velocity along the width of strip at the exit of the roll bite and the spread of strip for the different crown factors are presented in this paper. The modelling of the shape, profile and flatness for cold rolling of thin strip with friction variation is also discussed.
Keywords: Shape; Profile and flatness; Friction variation; Thin strip rolling; Rigid plastic FEM; Modelling

1. Introduction Increasing applications of the thin strip and high quality requirement compels steel manufacturers to improve its manufacturing quality and productivity in order to maintain competitiveness in the strip rolling industry. One of the important features of the thin strip is the shape and profile [1] of the strip, which affects the operation of rolling process and the quality of strip. Using the rolling mills to produce thinner strip, is one of the major efforts for steel manufacturers. However, the rolling of thin strip on the rolling mill will introduce some problems, such as shape and profile of strip (see Fig. 1, there is an edge drop). It is a challenge for researchers to overcome these problems. Friction at the interface of strip and work rolls has a significant effect on the mechanics of the rolled strip. Traditional approach is to assume that the frictional force in the roll bite is proportional to the normal force, with the friction coefficient remaining a constant in the roll bite. However, this will incur a loss of accuracy in the roll gap model, and affect the shape and profile of the strip. In order to understand the friction mechanism in metal rolling

processes, previous research has been made in both experiments and theoretical modelling. Lenard [2] and Liu et al [3] have shown that the friction varies in the roll bite, Lenard [4] also showed that the friction coefficient varies with the reduction. The friction variation affects the rolling force and the accuracy of