Finite Element Analysis of Four-Roll Pass Cold Rolling

Abstract

This paper presents a study of the mechanics of deformation of the four-roll pass cold rolling using an elastic-plastic finite element program. This process has been developed at the Anshan Institute of Iron and Steel Technology, People's Republic of China, where a new four-roll pass small section cold rolling mill has been built. The initial finite element analysis has been carried out for the rolling of 8 mm square section bar from 10 mm diameter round stock under dry friction conditions. The results show clearly how the areas of plastic deformation develop during the rolling process. The distributions of the generalized stress and the generalized plastic strain, both on the longitudinal symmetrical plane and on the transverse cross-sections of the workpiece, have been obtained, and the pressure distribution along the arc of contact has been determined. In addition, the roll separation force and the pass elongation of the workpiece predicted by the finite element program have been compared with the corresponding values measured in experiments when rolling 6.5 mm square section bar from 8 mm round material with machine oil lubrication. Good agreement has been obtained.