Finite-slab element investigation of square-to-round multi-pass shape rolling

Abstract

Roll-pass design for the rolling of shapes remains an expensive experience based trial-and-error process. Consequently, analysis and optimization of roll-pass design remain important objectives. This paper presents results of an analysis of a seven pass square-to-round sequence using a computationally effective quasi-three dimensional finite-slab element code, tasks. Simulation results are compared with results obtained from a previous experimental study reported in literature. Calculated values of exit cross-sectional areas and roll separating forces agree well with experimental values. However, the assumption of generalized plane strain results in slightly higher roll forces. tasks also calculates detail distributions of effective strain and effective strain-rate for each of the seven passes and provides information on the development of the plastic zone (strain rate) in each pass and the accumulation of deformation during the rolling sequence. Therefore, the effect of roll-pass sequence design on the roll forces and the quality (distribution of strain) of the rolled product can be studied. Since simulation of each roll pass takes about 30 minutes of cpu time on a micro VAX computer system, this code has the potential for use in the redesign of roll-pass schedules for improved product property.