A Computational and Experimental Study of Cold Rolling of Aluminum Alloys With Edge Cracking

[+] Author and Article Information
S. Ghosh, D. Gardiner

Department of Mechanical Engineering, The Ohio State University, Columbus, OH 43210

M. Li

Section Head, Process Mechanics, Alcoa Technical Center, Alcoa Center, PA 15069

J. Manuf. Sci. Eng 126(1), 74-82 (Mar 18, 2004) (9 pages) doi:10.1115/1.1645877 History: Received October 01, 2003; Online March 18, 2004
Copyright © 2004 by ASME
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Micrograph showing edge cracking occurring on the finished edge of an aluminum alloy strip during cold rolling to a reduction ratio of 80%
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A schematic diagram of the cold rolling process showing process parameters and boundary conditions
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Uniaxial stress-plastic strain curves obtained from compression tests of aluminum alloys (a) AA5049, (b) AA5086
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A photograph of the Fenn Mill showing various mechanisms
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(a) Force and (b) torque measurement data obtained during the steady-state part of rolling experiments with the AA5049 alloy for 20% reduction ratio
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Experimental and numerical values of the roll force as functions of the reduction ratio for various values of Coulomb friction coefficient
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Simulated values of the roll force plotted for different values of the limiting shear stress at (a) 20% reduction ratio, (b) 35% reduction ratio, (c) 50% reduction ratio
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Comparison of (a) roll force and (b) roll torque obtained with the friction model (σ=0.25, τ0=82.7 MPa) with the experimental results for the AA5049 alloy
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Contour plots of (a) effective stress, (b) equivalent plastic strain, (c) void volume fraction in the Gurson model and (d) damage parameter in the Cockcroft Latham model, for 20% cold rolling simulations of AA5049 alloy
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Contour plots of (a) effective stress, (b) equivalent plastic strain and (c) void volume fraction for the Gurson model for plane strain simulations of AA5049 alloy to 20% reduction
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Comparison of (a) roll force and (b) roll torque predictions by various 2D and 3D models



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