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Open AccessArticle

Finite Element Analysis of Forward Slip in Micro Flexible Rolling of Thin Aluminium Strips

1
School of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Northfields Avenue, 2522 Wollongong, Australia
2
State Key Laboratory of Rolling and Automation, Northeastern University, Shenyang 110004, China
3
School of Materials and Metallurgy, University of Science and Technology Liaoning, Anshan 114051, China
*
Author to whom correspondence should be addressed.
Metals 2019, 9(10), 1062; https://doi.org/10.3390/met9101062
Received: 17 August 2019 / Revised: 18 September 2019 / Accepted: 19 September 2019 / Published: 29 September 2019
(This article belongs to the Special Issue Failure Mechanisms in Alloys)
This study delineates a novel finite element model to consider a pattern of process parameters affecting the forward slip in micro flexible rolling, which focuses on the thickness transition area of the rolled strip with thickness in the micrometre range. According to the strip marking method, the forward slip is obtained by comparison between the distance of the bumped ridges on the roll and that of the markings indented by the ridges, which not only simplifies the calculation process, but also maintains the accuracy as compared with theoretical estimates. The simulation results identify the qualitative and quantitative variations of forward slip with regard to the variations in the reduction, rolling speed, estimated friction coefficient and the ratio of strip thickness to grain size, respectively, which also locate the cases wherein the relative sliding happens between the strip and the roll. The developed grain-based finite element model featuring 3D Voronoi tessellations allows for the investigation of the scatter effect of forward slip, which gets strengthened by the enhanced effect of every single grain attributed to the dispersion of fewer grains in a thinner strip with respect to constant grain size. The multilinear regression analysis is performed to establish a statistical model based upon the simulation results, which has been proven to be accurate in quantitatively describing the relationship between the forward slip and the aforementioned process parameters by considering both correlation and error analyses. The magnitudes of each process parameter affecting forward slip are also determined by variance analysis. View Full-Text
Keywords: finite element analysis; forward slip prediction; strip marking method; multilinear regression; micro flexible rolling; thickness transition area; 3D Voronoi modelling finite element analysis; forward slip prediction; strip marking method; multilinear regression; micro flexible rolling; thickness transition area; 3D Voronoi modelling
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MDPI and ACS Style

Qu, F.; Xu, J.; Jiang, Z. Finite Element Analysis of Forward Slip in Micro Flexible Rolling of Thin Aluminium Strips. Metals 2019, 9, 1062.

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