Analysis of the non-steady state vertical–horizontal rolling process in roughing trains by the three-dimensional finite element method

The vertical–horizontal rolling process is often used to accomplish width reduction so as to provide a synchronising operation between the continuous slab casting and hot rolling processes. Numerical simulation of the non-steady state deformation behaviour around the head and tail ends during this process is made by the full three-dimensional rigid–plastic finite element method. An explanation is provided in the theory for the ‘thin element technique’ at the inlet surface of velocity discontinuity. To deal with the interpolation of friction within a surface of an element contacting partly with the roll, a new term, so-called ‘pseudo shape function’, is presented and a related new equation formula is deduced. The calculated shape of the slab edge, the separating force and the rolling torque are consistent with those measured experimental ones for the model material lead.