A coupled finite element method for a three-dimensional analysis of the flat rolling of aluminum with different reductions

In this paper, the authors have developed a finite element model to establish a heat transfer finite element model and a three-dimensional large deformation thermo elastic–plastic finite element model, which is then coupled to form a complete theoretical model including heat transfer. In this theoretical model, the two variables of element deformation and temperature variation are placed in a variable matrix. The thermo elastic–plastic stiffness matrix and heat transfer stiffness matrix are placed in the same expansion stiffness matrix. Furthermore, a three-dimensional numerical simulation model of metal rolling formation is developed from the theoretical model. The numerical simulation model developed in this paper was used to simulate aluminum strip rolling. Simulation of the rolling process of aluminum strips in cold rolling and hot rolling under different reductions of the strip were conducted to obtain the effects of different reductions of the strip on rolling, and obtain related reference date for the practical rolling process. The simulation results were compared with experimental values to verify the feasibility of the theoretical model and numerical simulation model established in this study. The simulation presented in this paper indicates that regardless of cold rolling or hot rolling, a greater reduction increases the rolling force and strain rate, and it also produces greater residual stress and temperature rise. Further, the bulging on the sides and the crater on the end face are positively correlated with the reduction of the strip.