Application of 3D FEM-slab method to shape rolling

In this paper, a complex model combining the simplicity of the slab method and accuracy of the finite element method was developed to save CPU time. When applied for the shape rolling, the deformation zone in the billet was divided into several proper slabs according to the shape of boundaries, in which each slab must match the force equilibrium along the longitudinal direction. Then, FEM was used to calculate sequentially the velocity field, metal flow, stress and strain distribution for each slab. By using only one slab in each iteration, the iteration range of traditional FEM was significantly reduced. Therefore, the memory capacity and computational time can be significantly reduced. Compared with traditional FEM, the results of this complex model were acceptable, verifying that the model proposed in this paper is an effective method.