Asymptotically Modelling Plastic Deformation during Cold Rolling of Sheet Metal #

Mozhdeh Erfanian, Ed Brambley, Francis Flanagan, Doireann O’Kiely

15:10 Monday in 4Q05.

Part of the Solid mechanics session.

Abstract #

Cold rolling is a metal forming process where a strip of metal passes between two rollers and comes out thinner. Understanding the stress and strain in the material resulting from the roll pressure is essential not only for process design but also for material design. Established mathematical models for rolling make unjustified adhoc assumptions (for example, assuming the deformation is vertically homogeneous), and are not well validated due to a lack of reliable experimental or numerical data. Here, we present a multiple-scale asymptotic model for cold rolling under the assumption of large rollers and a thin sheet. This model can successfully predict the stress and strain distribution, including through-thickness stress oscillations, and is shown to agree well with Finite Element simulations. The results also suggest a possible origin of residual stress in the resulting strip. This modelling approach has potential applications in many metal forming processes due to its accuracy, simplicity and quick computation.