Internal defects prediction in flat rolling process: theoretical analysis and experimental verification

Abstract

In this paper, the upper bound method has been used to analyze of flat rolling process and prediction of internal defects for rigid plastic materials. The inlet and outlet shear boundaries of the deformation region are assumed to be arbitrarily curved surfaces. A unified kinematically admissible velocity field has been proposed. This field permits the possible formation of internal defects during the rolling process. A criterion has been presented to predict the occurrence of split ends and central burst defects during the flat rolling process for a given rolling condition. The corresponding results are compared with some experiments performed by authors and also with the theoretical published data. These comparisons show a good agreement. Finally, the effects of the reduction in area on the safe and unsafe zones are investigated.