The effect of roll and clad sheet geometry on the necking instability during rolling of clad sheet metals

Experimental evidence is presented showing that the rolling strain required to produce internal necking in clad sheet depends both on the volume fraction of each constituent in the clad and the geometry of the rolls. This result was not predicted by earlier localization analysis that approximates the stress/strain field in rolling with that of plane strain compression. The evolution of hardness during rolling and complementary finite element results point to redundant shearing of the soft phase as the reason for this behavior. Such redundant shear differentially strengthens the softer component of the clad and reduces the induced tensile stress in the harder component, delaying the localization. Therefore, unwanted strain localization in rolling of clad sheets can be delayed significantly by the use of small radius rolls in configurations such as a Sendzimir mill.