A simulation of three-dimensional metal rolling processes by rigid–plastic finite element method

Using different frictional shear stress models, mesh division and number of elements in the deformation zone, this paper focuses on analysing the influence of friction variation on the convergence and results of simulation such as rolling pressure, forward slip and spread by 3D rigid–plastic FEM. The effects of mesh division and the number of elements on the precision, stability and convergence of the simulation are also discussed. This investigation shows that the frictional shear stress model with a variation in the deformation zone can provide satisfactory results that are in good agreement with experimental values, and are also more accurate than results from other methods. Suitable mesh division can improve the precision and effectiveness of the simulation. The results of the simulation are discussed for front and back tensions.