A design sensitivity analysis scheme is proposed for an elasto-plastic finite element analysis with explicit time integration using a direct differentiation method (DDM). The direct differentiation scheme proposed deals with large deformation, an elasto-p

Based on the ABAQUS/Explicit code, the authors, in this paper, analyse the roll bite for the thin strip rolling, and focus on the modelling of the deformation in a roll bite zone, considering cases with and without tension. An elastic–plastic finite element (FE) model to simulate the hump at elastic entry zone and the elastic recovery at exit zone is developed. The effect of tension on the humps can be quantified, which helps to improve the accuracy of the final product. The relationship between the hump value and rolling speed in the roll bite are also obtained from the simulation. The calculated rolling force and elastic strain at entry zone are close to the measured and theoretical values, respectively. This research can model the deformation features of strip in the roll bite, predict the elastic recovery value of strip and improve the accuracy of final products through a correct roll gap set up.