Thermal-Mechanical Modelling of the Flat Rolling Process

1 Introduction.- 2 Material Properties and Interfacial Friction.- 2.1 Resistance to Deformation.- 2.1.1 Empirical Constitutive Relations for Carbon Steels.- 2.1.2 High Strength Low Alloy Steels.- 2.1.3 Representation of the Results of Compression Tests.- 2.2 Friction in the Flat Rolling Process.- 2.2.1 Friction as a Function of Process and Material Parameters.- 2.2.2 Interfacial Forces in the Roll Gap During Flat Rolling.- 2.2.3 Discussion.- 3 One-Dimensional Models of Flat Rolling.- 3.1 Conventional Models.- 3.1.1 Orowan's Theory.- 3.1.2 Sims' Method.- 3.1.3 Bland and Ford's Technique.- 3.1.4 Ford and Alexander's Method.- 3.1.5 Tselikov's Solution.- 3.2 Refinement of the Conventional Models.- 3.2.1 Derivation of the Basic Equations.- 3.2.2 Roll Deformation.- 3.2.3 Roll Force and Roll Torque.- 3.3 Comparison of Mathematical Models of Flat Rolling.- 3.3.1 Comparison of Assumptions in Various Models.- 3.3.2 Statistical Analysis of Predictive Capabilities.- 3.4 Further Substantiation of the Predictive Capabilities of One- Dimensional Models.- 4 Thermal-Mechanical Finite-Element Modelling of Flat Rolling.- 4.1 Rigid-Plastic Finite-Element Method.- 4.1.1 Description of the Method.- 4.1.2 Boundary Conditions.- 4.1.3 Structure of the Computer Program.- 4.2 Heat Transfer.- 4.2.1 Numerical Solution of the Fourier Equation.- 4.2.2 Steady State Model With Convection.- 4.3 Results of Computations.- 4.3.1 Hot Rolling.- 4.3.2 Cold Rolling.- 4.4 Experimental Substantiation of the Model's Predictions.- 4.4.1 Hot Rolling of Steel.- 4.4.2 Warm Rolling of Aluminium.- 4.4.3 Cold Rolling of Aluminium.- 4.5. Role of the Heat Transfer Coefficient.- 5 The Role of the Shape Coefficient in Modelling of the Flat Rolling Process.- 5.1 Correlation between the Shape Coefficient and Load Parameters.- 5.1.1 The Effect of ? on the Friction Stresses.- 5.1.2 The Effect of ? on Forces and Torques.- 5.2 The Effect of the Shape Coefficient on Strain and Strain Rate Distributions.- 5.2.1 Finite-Element Analysis of Strain Rate Fields for Various Shape Coefficients.- 5.2.2 Efficiency of the Rolling Process.- 6 Conclusions.- References.- Author Index.