Abstract
A complete mathematical model of the Variable Gap flat-Rolling (VGR) process for producing components with variable thickness under hot working conditions is presented. The model is composed of separate submodels for deformation, flow stress, roll force and temperature. Sub-modelling approach allows changes and new developments to be easily incorporated. A three-dimensional deformation analysis of the workpiece based on the upper bound theorem is carried out. A simple velocity field is proposed. To preserve the theoretical consistency, an equivalent coefficient of friction is adopted for roll force calculation. Furthermore, the basic assumption of rigid perfectly-plastic material is modified by introducing the concept of isotropic rate-dependency. Satisfactory results were obtained in spread, torque and force prediction.
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