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ANALYSIS OF COLD ROLLING PROCESS WITH DIFFERENT PARAMETERS

USING FINITE ELEMENT METHOD

Conference Paper · November 2018

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 International Conference 8th-9th of November 2018

on Advances in Mechanical Faculty of Engineering and

Natural Sciences
and Mechatronics
Ankara Yıldırım Beyazıt
Engineering University, Ankara, Turkey

Full Paper Proceeding

http://aybu.edu.tr/icammen2018/
 1st International Conference on Advances in Mechanical and Mechatronics
Engineering
ICAMMEN 2018
8-9 Nov 2018, ANKARA

ANALYSIS OF COLD ROLLING PROCESS WITH DIFFERENT PARAMETERS

USING FINITE ELEMENT METHOD

Jabbar 𝐆𝐚𝐭𝐭𝐦𝐚𝐡𝟏 , Fahrettin 𝐎𝐳𝐭𝐮𝐫𝐤 𝟐,𝟑 , 𝐒𝐚𝐝𝐞𝐭𝐭𝐢𝐧 𝐎𝐫𝐡𝐚𝐧𝟐

1
Department of Material Engineering, College of Engineering, University of Diyala, Diyala, Iraq
2
Department of Mechanical Engineering, Ankara Yildirim Beyazit University, Ankara, Turkey
3
Turkish Aerospace Industries, Inc., Ankara, Turkey

Corresponding Author: Jabbar Gattmah, E-mail: msc_jgj_katma7@yahoo.com

ABSTRACT

In this study, a commercially available finite element software ABAQUS/Explicit is used to simulate a cold rolling
process for a rectangular cross-section. AA5049, AISI1015, and 304L stainless steel materials are considered in
rectangular bar shape. Effects of process parameters on the rolling process are studied in detail. The finite element
model is validated with available experimental data. Results indicate that the material type has a great influence
on determining the reduction of area, friction coefficient, and roller speed. The maximum von Mises stress is
increased with increasing reduction of area and roller speed for AA5049 and it is almost constant for 304L stainless
steel.

Keywords: Finite element method, rolling simulation, cold rolling, rolling process, rolling parameters.

1. INTRODUCTION
Cold rolling is one of the widely used manufacturing processes in metal forming industry. Different cross-sections
including beam, channel, angle, bar, rod, and seamless pipe can be produced [1]. In the rolling process, there are
two rotating rolls used to reduce thickness of the material while the length of the material is increased. These
rollers work on the same plane and have the same geometry, one above the other with the opposite direction. Fig.
1 describes a schematic of a cold rolling process with a plastic zone. Where 𝜔 represents the angular velocity of
roller and 𝛼 is the angle of rolling contact between rolls and workpieces while ℎ𝑜 and ℎ𝑓 are the thickness of
workpieces before and after rolling respectively. Reduction of material thickness is the main objective for the cold
rolling process. During the process, the complexity of metal flow due to the deformation in the contact zone
between rolls and material is taken place. The deformation of workpieces is quite complex due to the reduction of
area that produces axial and radial stresses and strains. Many parameters like the roller speed, the speed of
workpiece, the reduction in thickness, the roller diameters, and the friction coefficient have affected the rolling
process [2-3]. In metal forming processes, the rolling, drawing, and extrusion problems can be solved using finite
element method. Simulation work reduces development and manufacturing times and cost signıficantly. These
processes consist of large deformation and complex contact issues. For this purpose, the time explicit dynamic
analysis is generally utilized to solve large deformation and contact problem. The method is applied to describe
the behavior of the internal stresses and plastic strains [4-5]. Several studies have been performed on the subject.
In one of the study, rolling process of aluminum alloys were simulated by the finite element method and compared
to experiments models [6]. Both the experimental and numerical results were in good consistency. The static cross-
sectional for the strip thickness profile was predicted using a computational method and model deflection of the
cluster-type rolling mill components [7]. Park and Anh [8]. studied longitudinal strain and springback phenomenon
that take place during the cold rolling of aluminum automotive components. An Arbitrary Lagrangian Eulerian
technique was utilized to model chatter vibration in high speed rolling by finite element method [9]. The results
were found consistent with experimental data. Cold rolling parameters are quite important in determining the
quality of products. They are critical to achieve the rolling process at the lowest cost. Cold rolling process
parameters for thin steel strips were determined to prevent the chatter which occurs by increasing the limit of

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rolling speed [10]. Finite element analysis based on DEFORM-3D software was applied to simulate train axle
cross wedge rolling. The tangential, axial and radial forces were calculated to compare the differences between
round and square billet rolling [11]. The wedge rolling process was developed using the numerical method based
on the LS-DYNA and experimental method to analyze the process parameters of the complex profile rolling [12].
Theoretical and experimental rolling of bars on a three-high skew rolling mill of aluminum was investigated with
a single pass. Stefanik et al. [13] determined the state of deformation, stress, and temperature distribution during
the process. The working roller was considered in a four-high rolling mill using by finite element method based
on the dynamic analysis. Kapil et al. [.14] selected different parameters of the rolling process to calculate the forces
acting on the working rollers. The dynamic model was performed to analyze the cold rolling process by combining
the electromechanical model and the deformation zone model. The results based on kinematic parameters, force,
and energy parameters were obtained [15]. Artificial neural networks were also used to predict the effect of Inter-
Stand tensions in controlling on other parameters such as the rolling pressure, the rolling force, the forward and
backward slips, and the neutral angle [16]. Jurkovic et al. [17] performed the real production conditions of the cold
rolling process of channels section using the theoretical approach and the complex experimental procedure to
measure the force and deflection for the rolls.

Aforementioned studies clearly reveal that the simulation of the cold rolling process is difficult. In addition, there
is also an urgent need to understand the behavior of stresses and plastic strains produced during the process. In this
research, AA5049 aluminum, AISI1015 low carbon steel, and 304L stainless steel materials were considered in
rectangular bar shape. The objective of this paper is to use the finite element method based on Explicit
Dynamic/ABAQUS to study effects of the reduction of area, the friction coefficient between surfaces of rollers
and bar, as well as rollers speed on von Mises stress and equivalent plastic strain during the process.

Figure 1. A schematic of rolling process with deformation

2. THE FINITE ELEMENT MODEL OF COLD ROLLING PROCESS

The cold rolling process was analyzed by finite element method. The three-dimensional dynamic explicit model
was developed by using a commercially available software ABAQUS TM . The rectangular cross-section bar was
considered as a deformable body and two rollers were defined as rigid bodies with a constant diameter and
thickness 140 mm and 30 mm, respectively. Initial dimensions of the workpiece were constant 40 mm in length,
20 mm in width, and 8 mm thick while final dimensions were changed and depend on the reduction of area. The
reductions of 19%, 25%, and 31% were selected for reducing the initial thicknesses to 6.5 mm, 6 mm, and 5.5 mm
respectively. AA5049, AISI1015, and 304L stainless steel materials were considered. The mechanical properties
for these materials as well as the true stress and true plastic strain were applied according to the available data in
literature [6,18-19]. The assembly definition of the symmetry rolling model includes two parts: the roller and the
initial rectangular bar. The assembly was mated using the “dependent option” to assemble these two parts. The
“translate instance option” was used to move parts to their correct positions.
In this study, the explicit dynamic analysis method was applied. It is defined as a mathematical technique for
integrating the equations of motion through time. This technique is used to solve the problems that contain large
deformation and nonlinear material response as in the case of the cold rolling process. Due to the contact between
rollers surface and material surface, the penalty method with finite sliding for the surface to surface was utilized
to resolve the tangential behavior of a mechanical contact [20]. The Coulomb friction is the basic role to define

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compressive force that is proportional to the penetration of the material. Tangential behavior, and magnitude of
friction coefficient were considered. Coefficients of friction 0.1, 0.2, and 0.3 were selected for all simulation
models.
Definition of boundary conditions were quite difficult. Therefore, it must be applied correctly for obtaining the
accurate results with a minimum error. For the cold rolling process, the initial boundary condition was the velocity
of the bar while roller speed defined as an angular velocity. In this study, the liner velocity of the bar was constant
350 mm/sec that was defined according to the predefined field option. Different angular velocities were given to
rotating the rollers and the reference center point was fixed at the directions of (U1, U2, U3, UR1, UR2=0) while
the direction of (UR3≠0). The roller speed was given by VR3 direction as 10, 20, and 30 rad/sec. Because the
rolling model had a symmetry, the half model was considered. Meshes and elements were displayed in Fig. 2.
Element type was C3D8R which has 8-node linear brick, reduced integration, hourglass control. The number of
elements for the initial workpiece (bar) were 25600 while for the rigid roller, 2189 elements were created.

Figure 2. Finite element meshing

3. MODELS VALIDATION
Finite element modeling of the cold rolling process was validated with the experimental results in the literature
[6], as presented in Fig. 3. For the validation procedure, AA5049, diameter of roll was 148.8 mm, and reduction
of areas were 20, 35, and 50%. The initial thickness was 6.13 mm and reduced to 4.91 mm, 3.94 mm, and 3.02
mm. The dimensions of the strip were 38.1 mm in length and 43.6 mm in width. The friction coefficient was 0.23,
roller speed was 12 rad/sec, and the linear velocity of the strip was 381 mm/sec. From the Fig. 3, the results show
a good coherence between the finite element and experimental results with some variation. It can be seen that both
the simulation and experimental models have the same behavior, the roll force increases with increasing the
reduction of area due to the increase in plastic deformation at inlet and outlet of forming zones. This validation
proves that the initial boundary conditions for the simulation models were correctly applied. Experimentally, the
roll forces were recorded 149, 212, and 225 kN at the reduction of areas of 20, 35, and 50%. For the finite element
results, the roll forces were calculated as 165, 235, and 280 kN at the reduction of areas of 20, 35, and 50%. These
results clearly proved the validation of model.
300
EXP FEM

250
Roll Force (KN)

200

150

100
15 20 25 30 35 40 45 50 55
Reduction of Area (%)

Figure 3. Comparison of finite element and experimental results

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4. FINITE ELEMENT RESULTS

Simulations of the cold rolling process with explicit dynamic analysis software ABAQUS has been performed
with different materials and rolling parameters. The relationships between these parameters and the von Mises
stress and the equivalent plastic strain for various materials were shown, as well as the distribution of stress and
plastic strain were presented.

4.1 von Mises Stress with Different Materials and Reduction of Areas
The Fig. 4 illustrates the distribution of von Mises stresses for various material at the reduction of area 31%,
friction coefficient 0.1, roller speed 10 rad/sec and step of time 0.075 sec. It can be observed that the values and
distribution of von Mises stress are different for each material. It is normal that the AA5049 has the least of strength
and maximum von Mises stress of 351.3 MPa was measured. The maximum von Mises stress for AISI1015 and
304L stainless steel 705.6 and 712 MPa were recorded respectively.

Figure 4. von Mises stress distribution for (a) AA5049, (b) AISI1015, and (c) 304L stainless steel

The Fig. 5 shows the relationship between maximum von Mises stress and the reduction of area for different
materials when friction coefficient of 0.2, roller speed of 10 rad/sec, and the step time of 0.1 sec. It can be seen
that the von Mises stress increases with increasing the reduction of area for all materials due to the increase in
plastic deformations in contact zone between material and rollers. The reason for this phenomenon was the increase
in reduction of area which needs the increased roll force [6]. This led to the increase in plastic deformation and
von Mises stresses. For the AISI1015 and 304L stainless steel, the maximum von Mises stress begins to approach
to each other when the reduction of area increases.
900
AA5049 AISI1015 304L Stainless Steel
800
Max. von Mises Sress (MPa)

700

600

500

400

300

200
18 20 22 24 26 28 30 32
Reduction of Area (%)

Figure 5. Relationship between maximum von Mises stress and reduction of area for different materials

4.2 Equivalent Plastic Strain with Different Materials and Friction Coefficients
The Fig. 6 presents equivalent plastic strain distribution for different materials at friction coefficient of 0.1,
reduction of area of 25%, roller speed of 10 rad/sec and step time of 0.09 sec. The figure shows that the maximum
of equivalent plastic strain PEEQ for the 304L stainless steel was 0.4754 while the maximum of equivalent plastic
strain PEEQ for the AA5049 and AISI1015 were 0.3842 and 0.411 in order. This means that the hard material
(304 stainless steel) gives the largest deformation compared to AISI1015 and AA5049. The plastic deformations
were increased at the contact zone between the material and the rollers because of the friction while at the center
of the thickness of bar the plastic deformations were the least.

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Figure 6. PEEQ distribution for (a) AA5049, (b) AISI1015, and (c) 304L stainless steel

Fig. 7 shows the relationship between maximum of equivalent plastic strain PEEQ and friction coefficient for
different materials at the reduction of area of 19%, roller speed of 10 rad/sec, and the step time of 0.075 sec. It
clearly observed that the equivalent plastic strain increases with increasing the friction coefficient. Because of the
contact between the surface of the rolls and the material surface, the friction forces try to prevent the movement
of material at rolling direction that leads to the increase of plastic deformation.

0.39 AA5049 AISI1015 304L Stainless Steel

Equivalent Plastic Strain PEEQ

0.37

0.35

0.33

0.31

0.29

0.27

0.25
0.05 0.1 0.15 0.2 0.25 0.3 0.35
Friction Coefficient
Figure 7. Relationship between maximum equivalent plastic strain and friction coefficient for different materials

4.3 von Mises Stress with Different Materials and Roller Speed
The Fig. 8 indicates the relationship between maximum von Mises stress and roller speed for different materials
when reduction of area was 31%, friction coefficient of 0.3, and the step time of 0.12 sec. Generally, the maximum
von Mises stress increases with increasing roller speed due to the increase of the roller work on the material [21].
Form the figure, the maximum of von Mises stress for AA5049 were 351, 380, and 390 MPa at roller speeds of
10, 20, and 30 rad/sec respectively. On the other hand, the maximum von Mises stress for the AA5049 was the
least compared to the two other materials. For both the AISI1015 and 304L stainless steel, the maximum of von
Mises stresses were close to each other compared to the AA5049 due to the difference of yield limit for the
material. The maximum of von Mises stress for AISI1015 was calculated 750 MPa at roller speed of 30 rad/sec.
For the 304L stainless steel, the maximum von Mises stresses were almost constant and determined as 760, 760.4,
and 760.5 MPa at roller speeds of 10, 20, and 30 rad/sec respectively. This means that the roller speed has minimum
effect on the von Mises stress when the material is hard.

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900
AA5049 AISI1015 304L Stainless Steel
800

Max. Von Mises Sress (MPa)

700

600

500

400

300
5 10 15 20 25 30 35
Roller Speed (rad/sec)

Figure 8. Relationship between maximum von Mises stress and roller speed for different materials

5. CONCLUSIONS
In this study, the finite element method was successfully utilized for the analyzing the cold rolling process.
Different materials of AA5049, AISI1015, and 304L stainless steel and different process parameters of the
reduction of area, the friction coefficient, and the roller speed were considered for the simulations of models.
Following conclusions were drawn:
1. The roll force increases with increasing reduction of areas.
2. The material type has a great influence on the selection of cold rolling parameters to determine maximum
von Mises stress and maximum equivalent plastic strain through the process.
3. Reduction of areas for the AA5049 has a great effect on the maximum von Mises stress while it is almost
constant for the 304L stainless steel at all reduction of areas.
4. Equivalent plastic strain PEEQ increases with increasing the friction coefficient for all materials.
5. The most interesting point is that the effect of roller speed has the different effects on maximum von Mises
stress. For the 304L stainless steel, there were little differences for the roller speed of 10, 20, and 30
rad/sec.

The recommendations for future works can be summarized as follows:

1. The effect of rolling parameters (roller diameter, reduction of area, roller speed, and friction coefficient)
on axial and radial residual stresses of the bar using experimental and finite element method can be
studied.
2. Analysis of chatter in cold strip rolling can be investigated both numerically and experimentally to
determine the optimal parameters of process.
3. Comparison between cold and hot rolling process according to the rolling force and the temperature that
give the least of residual stresses can be made.

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