Simulation of deformation and temperature in press roll piercing

A method of analyzing deformation and temperature in press roll piercing has been proposed. The method can be utilized for the pass design in the press roll piercing process. The method of analyzing deformation is ordinary three-dimensional rigid-plastic finite-element method (FEM), while for the analysis of temperature, three-dimensional FEM is primarily used; one-dimensional FDM is also used since three-dimensional FEM requires a large amount of computation time and memory capacity. Analysis was performed by varying the following rolling parameters: the pusher velocity, the plug position, the plug diameter, the plug top radius and the frictional factor between the material and the plug. Furthermore, the analysis of a perfectly rigid-plastic material was also performed. The effects of these rolling conditions on the roll force, the mandrel force, the material shape, the equivalent strain distribution and the temperature distribution are demonstrated. The roll force, the mandrel force and the material shape calculated from the analysis agree with those obtained by experiments.