Numerical simulations of asperity crushing using boundary conditions encountered in cold-rolling

in Key Engineering Materials [=KEM] (2013), 554-557

Asperity flattening has a huge influence on friction and wear in metal forming processes. Nevertheless, phenomena that occur at the microscopic scale are still not well understood. Since no experiment can ... [more ▼]

Asperity flattening has a huge influence on friction and wear in metal forming processes. Nevertheless, phenomena that occur at the microscopic scale are still not well understood. Since no experiment can be easily performed in real forming conditions, numerical models are essential to achieve a better knowledge of what happens in these contact regions. In this paper, two finite elements models are presented. The first one represents the flattening of a serrated asperity field in plane-strain conditions. The results are compared to the experiments published by Sutcliffe [1]. The second one is a tri-dimensional asperity model flattened by a rigid plane. The boundary conditions applied to this model correspond to the ones encountered in a real cold-rolling case. The results are compared to the relative contact area computed by a strip rolling model using the analytical laws proposed by Wilson & Sheu [2] and Marsault [3]. [less ▲]

Arbitrary Lagrangian Eulerian Modelling of Tension Levelling

in Matériaux et Techniques (2012, October), 100(Hors série 2012), 40-42

This paper presents a two-dimensional model of tension levelling using the Arbitrary Lagrangian Eulerian (ALE) approach. During the simulation, the ALE mesh remains globally fixed along the rolling ... [more ▼]

This paper presents a two-dimensional model of tension levelling using the Arbitrary Lagrangian Eulerian (ALE) approach. During the simulation, the ALE mesh remains globally fixed along the rolling direction. Therefore, the required number of finite elements is much smaller than in the Lagrangian case and smaller CPU times are obtained for the same accuracy on the results. The ALE model is first validated against a classical equivalent Lagrangian model. Then, both sets of numerical results are compared to experimental measurements from the pilot mill of ArcelorMittal Maizières R&D. [less ▲]

METALUB – A Slab Method Software for the Numerical Simulation of Mixed Lubrication Regime in Cold Strip Rolling

in Proceedings of the Institution of Mechanical Engineers - Part J - Journal of Engineering Tribology (2011), 225(9), 894-904

A cold rolling model taking into account mixed lubrication regime has been developed and included into a simulation software named MetaLub. The main objective is to enhance the performances of rolling ... [more ▼]

A cold rolling model taking into account mixed lubrication regime has been developed and included into a simulation software named MetaLub. The main objective is to enhance the performances of rolling mills from a lubrication point of view. It means that lubricant rheology but also roll diameters and roughness, etc., can be optimised to improve stability and efficiency of the rolling tool. The main features of MetaLub, are briefly presented in this paper. Then, two studies of the influence of rolling speed and negative forward slip are discussed. The obtained numerical results are presented and compared to some experimental data from literature and from ArcelorMittal facilities in order to validate the model and to show its capacity to understand and help to improve industrial rolling conditions. [less ▲]

Numerical Simulations of Asperity Crushing - Application to Cold Rolling

in Proceedings of ESAFORM : Belfast, 27-29th april 2011 (2011)

Asperity flattening has a huge influence on friction and wear in metal forming processes. Nevertheless, phenomena that occur at the microscopic scale are still not well understood. Since no experiments ... [more ▼]

Asperity flattening has a huge influence on friction and wear in metal forming processes. Nevertheless, phenomena that occur at the microscopic scale are still not well understood. Since no experiments can be easily performed in real forming conditions, numerical models are essential to achieve a better knowledge of what happens in these contact regions. In this paper, two finite elements models are presented. The first one represents the flattening of a serrated asperity field in plane strain conditions. The results are compared to the experiments conducted by Sutcliffe [1]. The second one is a tri-dimensional asperity model flattened by a rigid plane. The boundary conditions applied to this model correspond to the ones encountered in a real cold rolling case. The results are compared to the relative contact area computed by a strip rolling model using the analytical laws proposed by Wilson & Sheu [2] and Marsault [3]. [less ▲]