Analysis of asymmetric cold rolling using finite element method to create flat sheet

Abstract

In this paper, a simulation of asymmetric cold rolling is being presented by using an explicit analysis procedure. A two-dimensional finite element model with adaptive meshing technique has been employed to simulate asymmetrical condition, due to difference of the roll radius and velocity. Some conditions have been found to make sheet without curvature, in order to achieve this goal, different velocities have been made in rolls in each radius ratio. To validate the simulation, the results of the simulation has been compared with experimental papers which was done in the past. The effects of asymmetric process have been discussed, which is caused by radius ratio and velocity ratio on the rolling force, rolling torque and on the sheet curvature. Also the optimum velocity ratio in each radius ratio that causes the sheet without curvature was obtained. It was found that the appropriate speed ratio to produce flat sheets (i.e. sheets without curvature) is almost 1.067 being independent of the radius ratios between 1 and 1.05.