An ALE hydrodynamic lubrication finite element method with application to strip rolling

Abstract

A method that incorporates the hydrodynamic lubrication analysis into the arbitrary Lagrangian Eulerian (ALE) finite element analysis is developed for steady-state strip rolling simulation. By employing the ALE formulation, only part of thc workpiece, which is subjected to large plastic deformation within the roll-bite region, is modelled, so that thc computational cost is substantially reduced. In the hydrodynamic lubrication formulation, the effect of surface roughness on the lubricant flow is taken into consideration by the use of an average flow model. The friction stress is expressed in terms of forming variables such as surface roughness, lubricant and workpiece properties, film thickness, forming speed and process geometry. Furthermore, the elastic deformation of rolls is also analysed by the boundary element method to avoid the finite element discretization insidc the rolls. Two numerical examples. aluminium and steel strip rolling processes, are presented to demonstrate the merits of the proposed method.

A Lagrangian reproducing kernel particle method for metal forming analysis

“…Eulerian methods have been proposed to resolve the mesh distortion dif®culty [Zienkiewicz et al (1974[Zienkiewicz et al ( , 1984, Dawson (1978), and Hwu and Lenard (1988)]. The alternative ALE approaches combine the advantages of Lagrangian and Eulerian methods [Donea et al (1977), Belytschko et al (1978), Liu et al (1988Liu et al ( , 1991Liu et al ( , 1992, Hu et al (1993), Haber and Hariandja (1985), Ghosh and Kikuchi (1988), and Benson (1989)]. However, several drawbacks still exist in the ALE formulation.…”

Finite element method for mixed elastohydrodynamic lubrication of journal‐bearing systems

“…The asperity friction force a is then given by a = f a w a (27) where f a is the friction coefficient of the solid to solid contact.…”

“…The average Reynolds equation was used in the numerical simulations of sheet metal forming by Liu et al [27][28][29].…”

Design of large-deformation steady elastoplastic manufacturing processes. Part I: a displacement-based reference frame formulation

“…Arbitrary Lagrangian-Eulerian (ALE) kinematic descriptions, which combine both the Eulerian and Lagrangian descriptions, are also used to solve history-dependent problems [11][12][13][14][15][16][17][18]. ALE formulations are suitable for problems where the region of interest moves in a ÿxed domain, such as in crack propagation [16].…”

“…ALE formulations are suitable for problems where the region of interest moves in a ÿxed domain, such as in crack propagation [16]. Both velocity-based [12][13][14] and displacement-based [15][16][17][18] ALE formulations are reported.…”