A three-dimensional finite element analysis of the three-roll planetary mill

The purpose of this paper is to analyze the bar rolling process by means of the three-roll planetary mill with a three-dimensional elastic–plastic finite element model. The problems can be solved with the aid of finite element program MARC by adopting the large deformation—large strain theory with the updated Lagrangian formulation (ULF) and considering the contact problem between the rigid three-rolls and the deformable bar billet. In addition, a remeshing procedure was adopted to improve the unexpected run-time error of turning an element inside out. Furthermore, a new subdivided element model of the divided layers was created, and two different kinds of deformable bar billet were used to simulate the process. The numerical results obtained, such as the equivalent von Mises stress and plastic strain distribution, rolling force, rolling speed of the entrance and exit plane, etc., are very useful in designing the rolling process of the three-roll planetary mill.