Finite Element Analysis of Forward Slip in Micro Flexible Rolling of Thin Aluminium Strips

Abstract

This study delineates a novel finite element model to consider a pattern of process parameters affecting the forward slip in micro flexible rolling, which focuses on the thickness transition area of the rolled strip with thickness in the micrometre range. According to the strip marking method, the forward slip is obtained by comparison between the distance of the bumped ridges on the roll and that of the markings indented by the ridges, which not only simplifies the calculation process, but also maintains the accuracy as compared with theoretical estimates. The simulation results identify the qualitative and quantitative variations of forward slip with regard to the variations in the reduction, rolling speed, estimated friction coefficient and the ratio of strip thickness to grain size, respectively, which also locate the cases wherein the relative sliding happens between the strip and the roll. The developed grain-based finite element model featuring 3D Voronoi tessellations allows for the investigation of the scatter effect of forward slip, which gets strengthened by the enhanced effect of every single grain attributed to the dispersion of fewer grains in a thinner strip with respect to constant grain size. The multilinear regression analysis is performed to establish a statistical model based upon the simulation results, which has been proven to be accurate in quantitatively describing the relationship between the forward slip and the aforementioned process parameters by considering both correlation and error analyses. The magnitudes of each process parameter affecting forward slip are also determined by variance analysis.

Failure Mechanisms in Alloys

“…More specifically, the broad category of static overload includes more generic subjects also from the field of manufacturing-related topics, where the effect of deformation and fracture was studied as an important and undetached ingredient of the fabrication process per se (e.g., hot and cold working, machining). Therefore, the mostly "intense area" (Overload/Static) comprises studies concerning general deformation and fracture phenomena, as the result of instant loading/testing conditions [4,9,10,14,15,19] and studies related to manufacturing and production processes [6,7,12,13,16,20,22,25,26]. Testing and modeling procedures addressing the evolution of deformation and fracture during forming [7,13,26], the impact toughness, [4] and certain production process characteristics [25] are also included.…”

“…Therefore, the mostly "intense area" (Overload/Static) comprises studies concerning general deformation and fracture phenomena, as the result of instant loading/testing conditions [4,9,10,14,15,19] and studies related to manufacturing and production processes [6,7,12,13,16,20,22,25,26]. Testing and modeling procedures addressing the evolution of deformation and fracture during forming [7,13,26], the impact toughness, [4] and certain production process characteristics [25] are also included. Nevertheless, shear fracture processes that emerged in machining and chip formation are also part of this broader group of studies, relevant to manufacturing topics (see [12,16,20]).…”

“…(i) Casting and Metal Forming [6,7,11,13,15,19,[24][25][26] (ii) Machining [12,16,20] (iii) Chemical/Petrochemical [3,17,21,23] (iv) Heat Treatment [22] (v) General Plant Machinery [1,9,18,24] b. Fatigue and Cyclic Loading [8,9,18]; c. Corrosion and Environmentally Assisted Cracking [3,5,11,21]; d. Wear and Surface Degradation [1,24,27].…”

“…(i) Casting and Metal Forming [6,7,11,13,15,19,[24][25][26] (ii) Machining [12,16,20] (iii) Chemical/Petrochemical [3,17,21,23] (iv) Heat Treatment [22] (v) General Plant Machinery [1,9,18,24] The metal component manufacturing industry (casting, metal forming, and machining) seems to be highly involved, as one of the primary industrial component production sectors, in highlighting the efforts in understanding material behavior and taking actions for failure prediction and prevention.…”

Failure Mechanisms in Alloys

“…Combined (experimental, analytical, numerical model, etc.) [3,[6][7][8][12][13][14][15][16][18][19][20]22,25,26] As can be readily observed, the experimental and empirical approach is the dominant methodology of failure investigation. In addition, the emergence of numerical simulation, using finite element modeling (FEM), tends to be very popular in the prediction of material behavior and potential failure prevention.…”