Finite Element simulation of the edge-trimming/cold rolling sequence: Analysis of edge cracking

The aim of the present study is to develop a strategy of numerical simulation to study the sequencing of two processes, when the modeling geometry assumptions differ. In this study, the first process is assumed continuous, leading to a plane strain model. The developed strategy of simulation takes advantages of this assumption to extrude, in the out-of-plane direction, the 2D mesh and the mechanical fields to create a 3D model corresponding to the second process. In a previous experimental study achieved by the authors, an edge-trimming/strip thickness reduction sequence was analyzed. The aim was to quantify the effect of the work hardening accumulated in the first step on the occurrence of cracks in the strips edges during the second one. The present study uses this experimental sequence to validate the proposed approach and to better understand the reasons of edge cracking, according to the plastic strain level and thickness reduction conditions. Finally, the proposed approach is used as a predictor, to quantify the effect of a major parameter in edge-trimming on the strips edges integrity, at the end of the full sequence.