On the mechanism of cold rolling thin foil

Abstract

The deformation mechanism of cold rolling thin foil is investigated with the aid of the slab method in conjunction with an incremental analysis. The interaction between the rolls and foil is explored thoroughly. The effects of initial thickness and yield stress of foil materials are discussed in detail. Extensive numerical studies show that the pressure and shearing force profiles in the rolling bite vary significantly with the increment of reduction ratio. The distribution of slip and no-slip zones is much more complex than that predicted previously. In the regime of rolling extremely thin foils with a constant reduction ratio, the rolling load increases and the rolling torque decreases monotonically with decreasing inlet foil thickness. It is found, however, that the change of the central elastic/plastic no-slip zones has very little effect on the resultant rolling forces.