Application of Three Dimensional Finite Element Analysis to Shape Rolling Processes

In the present investigation, an FEM code SHPROL has been developed for three-dimensional simulations of shape rolling processes. SHPROL is capable of handling arbitrary roll profiles and follows the deformation path incrementally so that even the end deformation that causes the crop loss can be predicted. At the present time, SHPROL can be applied to isothermal rolling processes which consist of two equivalent rolls. The rigid-viscoplastic formulation is used and the constant shear friction, variable between sticking and frictionless, is utilized at the roll-billet interface. The roll profile is described as a combination of straight lines and arcs. To demonstrate the simulation capability of SHPROL, three rolling processes have been simulated: plane-strain rolling, plate rolling, and shape rolling from square to oval cross-section. Discussions were mostly made by comparing the simulation results to general observations in practice. The results show that SHPROL is a valuable tool for designing rolling processes in industrial importance.