Klaus Zeman, Alexander Kainz,
"Selected Rolling and Smart Material Simulations by Utilizing the Finite Element Package Deform"
: Third European Deform User's Conference 2004 (CD), 5-2004, Keywords: Hot Rolling Simulations, Thermo-mechanical coupling, Rigid-viscoplastic and elasto-viscoplastic constitutive laws, Magneto-rheological fluids, Squeeze mode, Parameter identification.
Selected Rolling and Smart Material Simulations by Utilizing the Finite Element Package Deform
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Third European Deform User's Conference 2004 (CD)
By utilizing the commercial finite element package Deform 3D , thermo-mechanically coupled massive forming processes can be simulated very efficiently. Within the frame of this simulation study, Deform 3D was applied to several highly praxis-relevant rolling scenarios, including the hot rolling of thick slabs, strips and plates, as well as combined roughing and edging passes to estimate the edging efficiency. Therefore, special emphasis was put on the detailed investigation of 3D-effects, such as lateral flow and strip spread, dog-bone formation (bulging) and back-spread of the dog-bones . Of considerable interest are thermo-mechanically coupled hot rolling simulations with several successive roughing or finishing mill passes. For the two borderline cases of total strain accumulation and total annealing (i.e. full recrystallisation) between two subsequent passes, the deformation behaviour of a metal block undergoing several rolling passes, e.g. seven roughing or nine plate mill passes incl. two 90-degree rotations, was analyzed in detail. Beside the determination of the deformed geometry, the temperature and the effective (logarithmic) strain distribution after each pass were of particular interest, as well as the time dependence of these quantities at selected observer points inside the rolling stock. For plate mill simulations, significant front end bending effects could be observed at the final passes, which can be attributed to a vertical symmetry breaking of either the geometry or the temperature distribution of the ingot.
Beside conventional metal forming simulations, novel smart materials like magneto-rheological (MR-) fluids can be treated to some extent by employing the concepts of massive forming processes. By employing Deform 2D in axially-symmetric geometry the massive forming behaviour of magneto-rheological fluids was simulated , which enables a deeper insight into the so far poorly understood non-linear squeeze-mode behaviour of MR-fluids.
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Keywords: Hot Rolling Simulations, Thermo-mechanical coupling, Rigid-viscoplastic and elasto-viscoplastic constitutive laws, Magneto-rheological fluids, Squeeze mode, Parameter identification.