Simulation of deformation and temperature in caliber rolling: effect of finite-element mesh in cross-section

We have proposed a method of numerical simulation for hot caliber rolling, in which the deformation of the material is analyzed by the conventional three-dimensional rigid–plastic finite-element method, while the temperature distribution in the material is calculated using a new combination of the three-dimensional finite-element method, two-dimensional finite-element method and one-dimensional finite-difference method. In this paper, the effect of the finite-element mesh in the cross-section of the material is examined. First, the following two types of finite-element mesh in the cross-section of the material is introduced: one type of finite-element mesh is derived from a mesh of square grids and the other type of finite-element mesh is derived from a mesh of concentric circles. Next, the shapes of the calibers for the first and the second rolling mill are designed so that round or square bars are produced from them after they are rolled twice. Finally, the analyses of square–diamond–square rolling, round–oval–round rolling and square–oval–square rolling are performed using the two types of finite-element mesh. As a result, the finite-element mesh derived from the mesh of concentric circles is proved to be more appropriate than the finite-element mesh derived from the mesh of square grids.