Investigation of the Efficiency of Roll Profiles and Technological Schemes of Deformation of Asymmetric Rolling in Relief Rolls of C11000 Copper Alloy by FEM Simulation

Abstract

In this paper, finite element simulation of asymmetric rolling in relief rolls of C11000 copper alloy in order to analyze the effectiveness of possible roll profiles and technological schemes of deformation was performed. The scientific innovation of this work lies in determining the patterns of development of stress-strain state parameters for various configurations of rolls, as well as determining the effectiveness of metal processing using various technological schemes. It was found that the use of trapezoidal relief makes it possible to increase the level of metal processing by almost 5 times compared with the use of radial relief. Comparison of technological schemes of deformation showed that deformation with 180° workpiece turning between passes significantly reduces the influence of the asymmetry factor. Deformation without changing the workpiece position between the passes has the opposite effect, and such a scheme significantly increases the influence of the asymmetry factor. Deformation with a transverse workpiece shift for the relief period between passes has the effect of a “golden mean.” The conducted laboratory experiment for lead billet showed that the shape change of lead billet during computer simulation has a high level of convergence with real conditions. At each stage of deformation, the difference in the geometric parameters of the workpiece between the model and the experiment did not exceed 3-5%. When deforming a copper billet, the maximum difference level was 8%, which is the result of the low rigidity of the rolling cage with smooth rolls.