Pesin A.M., Pustovoytov D.O., Shveeva T.V., Steblyanko V.L., Fedoseev S.A. Simulation of nonmonotonic metal flow during asymmetric sheet rolling with different velocities of the rolls

Abstract

Problem Statement (Relevance): Severe plastic deformation (SPD) techniques are used in the production of high-strength ultrafine-grained (UFG) metals and alloys. However, the existing SPD techniques seem to be lacking in practicality, especially when processing large-size construction materials such as steel sheets or strips. Conventional metal forming processes (for example, sheet rolling) can sometimes be described as SPD techniques because, under certain conditions, they can also cause high strains. However, there is an essensial difference between the conventional sheet rolling and SPD as the former implies monotonic strain whereas the latter – nonmonotonic strain. Therefore, it appears to be important to develop a new sheet rolling process that would provide nonmonotonic flow of metal under processing. In this regard, an asymmetric sheet rolling process with different peripheral velocities of the rolls offers a great potential. Objectives: The aim of the research was to apply mathematical modeling to analyse the relationship between nonmonotonic metal flow and strain intensity during a process of cold asymmetric sheet rolling with different peripheral velocities of the rolls. Methods Applied: The finite element method was applied for mathematical modeling together with the DEFORM 3D specialized software. Findings: It is demonstrated that rotation strain and shear strain provide a significant increment to the intensity of strain during asymmetric sheet rolling, which differentiates this process as an SPD technique. It is shown that nonmonotonic metal flow caused by asymmetric rolling results in an increased strain intensity (1.9 times) versus conventional rolling, all other conditions being equal. At the same time, nonmonotonic metal flow can cause the strip to sweep. Practical Relevance: The results of this research can be used to develop deformation scenarios for asymmetric sheet rolling aimed at obtaining UFG structure and high strength in metallic material.

Keywords

Severe plastic deformation, finite element method, nonmonotonic strain, asymmetric rolling, shear strain, aluminuim alloy.

Aleksander M. Pesin – D.Sc. (Eng.), Professor

Nosov Magnitogorsk State Technical University, Magnitogorsk, Russia. Phone: +7(3519)29-85-25. E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.. ORCID: http://orcid.org/0000-0002-5443-423X

Denis O. Pustovoytov – Ph.D. (Eng.), Assistant Professor

Tatiana V. Shveeva – Research Engineer

Nosov Magnitogorsk State Technical University, Magnitogorsk, Russia. E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.. ORCID: http://orcid.org/0000-0002-4726-6215

Valery L. Steblyanko – D.Sc. (Eng.), Professor

Nosov Magnitogorsk State Technical University, Magnitogorsk, Russia. E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

Sergei A. Fedoseev – D.Sc. (Eng.), Professor

Perm State National Research Polytechnic University, Russia. E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

1. Utyashev F.Z. Metal flow and structure formation during severe plastic deformation. Fizika i tekhnika vysokikh davleniy [High pressure physics and technology]. 2013, vol. 23, no. 1, pp. 45–55. (In Russ.).

2. Utyashev F.Z. The theoretical and applied aspects of production and application of bulk ultrafine-grained and nanostructured materials. Aviatsionno-kosmicheskaya tekhnika i tekhnologiya [Aerospace engineering and aerospace technology]. 2010, no. 9, pp. 12–18. (In Russ.)

3. Utyashev F.Z. The nanostructuring of metallic materials by severe plastic deformation. Fizika i tekhnika vysokikh davleniy [High pressure physics and technology]. 2010, vol. 20, no. 1, pp. 7–25. (In Russ.)

4. Ji Y.H., Park J.J. Development of severe plastic deformation by various asymmetric rolling processes. Materials Science and Engineering: A. 2009, vol. 499, pp. 14–17.

5. Bobor K., Hegedus Z., Gubicza J., Barkai I., Pekker P., Krallics G. Microstructure and mechanical properties of Al 7075 alloy processed by differential speed rolling. Mechanical Engineering. 2012, vol. 56, pp. 111–115.

6. Jianhua Jiang, Yi Ding, Fangqing Zuo, Aidang Shan. Mechanical properties and microstructures of ultrafine-grained pure aluminum by asymmetric rolling. Scripta Materialia. 2009, vol. 60, pp. 905–908.

7. Lorentz, Young Gun Ko. Microstructure evolution and mechanical properties of severely deformed Al alloy processed by differential speed rolling. Journal of Alloys and Compounds. 2012, vol. 536S, pp. S122–S125

8. Cui Q, Ohori K. Grain refinement of high purity aluminum by asymmetric rolling. Materials Science and Technology. 2000, vol. 16, pp. 1095–1101.

9. Zuo F., Jiang J., Shan A. Shear deformation and grain refinement in pure Al by asymmetric rolling. Transactions of Nonferrous Metals Society of China. 2008, vol. 18, pp. 774–777.

10. Pesin A., Pustovoytov D., Korchunov A., Wang K., Tang D., Mi Z. Finite element simulation of shear strain in various asymmetric cold rolling processes. Vestnik Magnitogorskogo Gosudarstvennogo Tekhnicheskogo Universiteta im. G.I. Nosova [Vestnik of Nosov Magnitogorsk State Technical University]. 2014, no. 4 (48), pp. 32–40. (In Russ.)

11. Pesin A., Pustovoytov D. Influence of process parameters on distribution of shear strain through sheet thickness in asymmetric rolling. Key Engineering Materials. 2014, vol. 622–623, pp. 929–935.