Research Papers

Prediction of Edge Crack in Cold Rolling of Silicon Steel Strip Based on an Extended Gurson–Tvergaard–Needleman Damage Model

[+] Author and Article Information
Quan Sun

Key Laboratory of Pressure System and Safety,
Ministry of Education,
East China University of Science and Technology,
130th Meilong Road,
Shanghai 200237, China
e-mail: sunquan0501@163.com

Jianjun Chen

Key Laboratory of Pressure System and Safety,
Ministry of Education,
East China University of Science and Technology,
130th Meilong Road,
Shanghai 200237, China
e-mail: jjchen@ecust.edu.cn

Hongliang Pan

Key Laboratory of Pressure System and Safety,
Ministry of Education,
East China University of Science and Technology,
130th Meilong Road,
Shanghai 200237, China
e-mail: hlpan@ecust.edu.cn

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received March 24, 2014; final manuscript received October 13, 2014; published online December 12, 2014. Assoc. Editor: Gracious Ngaile.

J. Manuf. Sci. Eng 137(2), 021003 (Apr 01, 2015) (6 pages) Paper No: MANU-14-1130; doi: 10.1115/1.4028827 History: Received March 24, 2014; Revised October 13, 2014; Online December 12, 2014

Edge cracking is commonly observed in cold rolling process. However, its failure mechanism is far from fully understanding due to the complex stresses and plastic flow conditions of steel strip under the rolling condition. In this paper, an extended Gurson–Tvergaard–Needleman (GTN) damage model coupled with Nahshon–Hutchinson shear damage mechanism was introduced to investigate the damage and fracture behavior of steel strip in cold rolling. The results show that extended GTN damage model is efficient in predicting the occurrence of edge crack in cold rolling, and the prediction is more accurate than that of the original GTN damage model. The edge cracking behavior under various cold rolling process parameters is investigated. It comes to the conclusion that edge crack extension increases with the increase of the reduction ratio, tension and the decrease of the roller radius and friction coefficient. The influence of shear damage becomes more significant in rolling condition with a larger reduction ratio, smaller roller radius, lower friction force, and tension.

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Fig. 1

A photograph of the experimental nonreversing two-high mill

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Fig. 2

Cold rolling specimen with precut notch

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Fig. 3

FE model of cold rolling process with boundary conditions and local mesh refinement

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Fig. 4

Experiment result of crack initiation around the notch tip after cold rolling

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Fig. 5

SEM photo of edge crack

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Fig. 6

The prediction of crack initiation after rolling based on (a) extended and (b) original GTN model

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Fig. 7

Evolution of damage component in rolling process

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Fig. 8

Results of (a) crack length and (b) normalized shear damage versus reduction ratio (R = 90 mm, μ = 0.1, tension = 0 MPa)

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Fig. 9

Results of (a) crack length and (b) normalized shear damage versus roller radius (ɛH = 40%, μ = 0.1, tension = 0 MPa)

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Fig. 10

Results of (a) crack length and (b) normalized shear damage versus friction coefficient (ɛH = 40%, R = 90 mm, tension = 0 MPa)

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Fig. 11

Results of (a) crack length and (b) normalized shear damage versus tension (ɛH = 40%, R = 90 mm, μ = 0.1)




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