Abstract
An efficient simulation method for predicting the width-spread in caliber rolling by the rigid-plastic finite element method is proposed. In this method, the three-dimensional deformation of the workpiece between the caliber rolls is simplified to the generalized plane-strain deformation where the strain rate is assumed to be uniform in the rolling direction over a cross section. Rolling by shaped rolls is treated as equivalent to compression with shaped dies, and the axial stress due to friction is taken into account. The deformed shape of a rectangular bar after caliber rolling is predicted and the calculated results of the width-spread are shown to agree with the experimental results. The deformed shape, the distribution of equivalent strain in the workpiece and the computing time are compared with those of the full three-dimesional simulation. The proposed simplified simulation method is found to provide sufficiently accurate results in terms of width-spread with a very short computing time.
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