A large-strain elastic-plastic finite element analysis of rolling process Original Research Article

A three-dimensional large-strain non-steady-state elastic-plastic finite element analysis has been performed for the flat rolling process. This analysis is based on E.H. Leeʹs theory of plasticity which begins with the decomposition of the deformation gradient into the product of elastic and plastic deformation gradients. The updated Lagrangian virtual work equations in incremental form and in rate form are derived. The detailed finite element procedures are outlined. The contact and frictional problem at the interface between the workpiece and the rolls is treated by using a modified Coulomb friction law. The numerical results, including the evolutions of the roll torque and roll forces, interfacial normal and shear stresses, lateral spread, spring-back, volume change, and stress distributions displayed on deformed shape, are presented and discussed.