Research on influence of rolling parameters on the rolling process based on numerical simulation

Rolling process involves geometric non-linearity, material non-linearity and boundary non-linearity, which is a complex and highly non-linear problem. It is impossible to obtain analytical solution in terms of trying to roll or physical experiment because of high cost, waste time and venture. Finite element method (FEM) is an effective one that can resolve large plastic deformation, thermo-mechanical coupling and complex boundary conditions between rollers and billet in the rolling process. FEM models of the rollers and billet are built by three-dimensional elastic?plastic FEM. The two-pass hot continuous rolling process of high-speed wire has been simulated accurately based on thermo-mechanical coupling condition. The equivalent of stress, equivalent of total strain and rolling force are computed for different initial rolling temperatures 1000°C and 1100°C. Furthermore, stress, strain, temperature and rolling force are also discussed for different gaps 8 mm and 12 mm, rolling velocities 1317 mm/s and 1379 mm/s and diameters of rollers 385 mm and 400 mm. The results of simulation supplied theoretical foundation for improvement of process plan, optimisation of process parameters, change of microstructure were also useful for practical manufacture.