Finite element simulation of a rolling process of aluminium

Jordan, Keith Ogak (2013) Finite element simulation of a rolling process of aluminium. Project Report. UTeM, Melaka. (Submitted)

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Abstract

Rolling in metal forming process is the process of reducing the thickness or changing the cross section of a long work piece by compressive forces applied through a set of rolls. Outcome of the rolling process don’t always turn out as they should be. It is important that the rolling process is simulated so that the outcome of the material can be examined so that time and cost can be optimized. There are two sets of results obtained in this study, static finite element analysis and dynamic finite element analysis of rolling process. For the static analysis, it is observed that the stress distribution along the arc of contact between roll and material (roll bite) is not uniform and increases from the entry to the exit of the roll bite. The strain that is produced by the force used in the static analysis is not as expected, because the force that moves and deforms the material is a combination of forces that acts with each other. For the dynamic analysis, it is observed that the exit thickness is not exactly as desired due to elastic relaxation of the material. Maximum stress occurs in the roll bite, and some stress is on the material after it has exited the roll bite. The strain in the material increases as it enters the roll bite and then decreases to a certain point as it exits the material. The velocity of the rolling process does not affect the deformation of the material because the stress and strain remains the same after a few trials in the analysis using different roll speeds. Careful application of stress and strain is important in the rolling process so that the outcome can be controlled to save time and cost during the rolling process and finite element analysis can be used to predict the behavior of material during the rolling process. iv

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