Modeling fatigue crack and spalling for rolling die under hot milling

Abstract

AbstractIn hot milling process, rolling die is subjected to nonsteady conditions which can rise the combinations of fatigue and spalling damage mechanism. An understanding about the failure mechanism of the rolling die is essential under hot rolling process. Fatigue crack growth and spalling process are governed by highly concentrated strain and stress in the crack tip region. Based on the theory of elastic‐plastic fracture mechanics, an analytical model are presented in this paper to determine the elliptical crack growth rate and spalling damage mechanism. The model includes new proposed constitutive equations for fatigue and spalling crack growth. To verify the models, finite element simulation and experimental data are considered. The results show good agreement with finite element simulation and experimental data.