Evolution of matt surface topography in aluminium pack rolling. Part I: model development

Roughening of the matt surface of pack rolled aluminium foil has been modelled. The model is based on the finite element method using isotropic plasticity. A distribution in material properties has been used to simulate the distribution of grain orientations through the material. It is found that the formation of shear bands causes roughening of the matt surface. The length of these shear bands allows individual grains or the hard roll to influence the roughness a significant distance away. Results show the effect of the ratio of the grain size to the strip thickness on the predicted roughness generated. The predictions show good qualitative agreement with the reported experiments. It is concluded that the model is able to simulate efficiently the effect of the granular behaviour of polycrystals on the matt surface roughness.