Bauman Moscow State Technical University (Moscow, Russia)

A. G. Zinyagin, Cand. Eng., Associate Prof., e-mail: ziniagin_ag@bmstu.ru
N. R. Borisenko, Post Graduate, e-mail: BorisenkoNikita17@yandex.ru
A. V. Muntin, Cand. Eng., Associate Prof., e-mail: muntin_av@bmstu.ru
M. O. Kryuchkova, Senior Lecturer, e-mail: mariya.mironova@bmstu.ru

This article discusses application of mathematical modeling based on the finite elements method (FEM) to analyze the process of rolling clad sheets and strips. Examples of studies are given, in which FEM was used to analyze the stress state at the interface between layers, to consider the effect of rolls speed mismatch on the rolling process, to determine the criteria for layer adhesion and other process parameters. However, some of these studies do not take into account a number of aspects that can increase modeling reliability. The article considers the most important aspects of development of the model for rolling clad sheets based on the FEM. Two main ways of modeling the clad and base layers are described, setting different properties of the same body or modeling layers by different contact bodies. Particular attention is paid to the choice of model parameters and the correct division of layers into elements to avoid loss of contact and penetration of elements into each other. This article also provides recommendations on the choice of friction coefficients for various contact pairs. When choosing friction coefficients, it is necessary to take into account the materials of the contact surfaces, their condition and operating conditions. In addition, the friction coefficient is an important factor affecting the accuracy of modeling, and it is recommended to compare the simulation results with experimental data to obtain its refined values. Examples of development of the models based on the FEM are given, which were adapted according to the results of laboratory experiments and applied to calculate the parameters of industrial rolling. Satisfactory convergence of modeling results with the results of industrial rolling is shown.
The researches were carried out within the RF program of strategic academic leadership “Prioritet-2030”, directed on support of development programs in higher education organizations, scientific project PRIOR/SN/NU/22/SP5/26 “Development of innovative digital tools for use of applied artificial intellect and advanced statistical analysis of Big Data in technological processes of manufacturing metallurgical products”.

1. Dunaev V. V., Muntin A. V., Samokhvalov M. V. et al. Features of manufacturing technology for large-size clad sheets and large diameter pipes made from these sheets. Metallurg. 2022. No. 9. pp. 23-30. DOI: 10.52351/00260827_2022_09_23
2. Kobelev A. G., Lysak V. I., Chernyshev V. N., Bykov A. A., Vostrikov V. P. Production of metallic layered composite materials. Moscow: Intermet Inzhiniring. 2002. 496 p.
3. Khaledi K., Rezaei S., Wulfinghoff S. Modeling of joining by plastic deformation using a bonding interface finite element. Int. J. Solid Struct. 2019. Vol. 160. pp. 68-79.
4. Da-Wei Zhang, Fang-Fang Xu, Zai-Chi Yu, Kun-Yin Lu, Ze-Bang Zheng, Sheng-Dun Zhao. Coulomb, Tresca and Coulomb-Tresca friction models used in analytical analysis for rolling process of external spline. Journal of Materials Processing Technology. 2021. Vol. 292. pp. 117059. DOI: 10.1016/j.jmatprotec.2021.117059
5. Murillo-Marrodán A., Garcia E., Cortés F. Friction Modelling of a Hot Rolling Process by means of the Finite Element Method. Proceedings of the World Congress on Engineering. UK, London. 2017 July 5-7. 2017. Vol. II. WCE.
6. Peng L., Lai X., Lee H. J., Song J. H., Ni J. Friction behavior modeling and analysis in micro/meso scale metal forming process. Mater. Des. 2010. Vol. 31. pp. 1953–1961.
7. Sverdlik M., Pesin A., Pustovoytov D., Perekhozhikh A. Numerical Research of Shear Strain in an Extreme Case of Asymmetric Rolling. Advanced Materials Research. 2013. Vol. 742. pp. 476–481.
8. Graça A., Vincze, G. A Short Review on the Finite Element Method for Asymmetric Rolling Processes. Metals. 2021. Vol. 11. p. 762. DOI: 10.3390/met11050762
9. Pustovoytov D., Pesin A., Biryukova O. Finite element analysis of strain gradients in aluminium alloy sheets processed by asymmetric rolling. Procedia Manuf. 2018. Vol. 15. pp. 129-136.
10. Nielsen C. V., Bay N. Overview of friction modeling in metal forming processes. Procedia Eng. 2017. Vol. 207. pp. 2257–2262.
11. Sun L., Ding J., Zhang J., Li H., Wang G. Numerical Simulation and Deformation Behavior of a Ti/Steel Clad Plate during the Rolling Process. Metals. 2023. Vol. 13. p. 218. DOI: 10.3390/met13020218
12. Qin Q., Zhang D., Zang Y., Guan B. A simulation study on the multi-pass rolling bond of 316L/Q345R stainless clad plate. Advances in Mechanical Engineering. 2015. Vol. 7 (7). DOI: 10.1177/1687814015594313
13. Yashin V. V., Beglov E. D., Aryshenskiy E. V., Latushkin I. A. Analysis of knurling of large-size ingots with clad material using finite element method. Proizvodstvo prokata. 2018. No. 1. pp. 24-29.
14. Gao B. X., Yu C., Xiao H. Aluminum/steel rolled composite finite element secondary development simulation and experimental study. IOP Conf. Series: Materials Science and Engineering. 2022. 1270. 012009.
15. Smirnov S., Veretennikova I. A., Vichuzhanin D. I. Modeling of delamination in multilayer metals produced by explosive welding under plastic deformation. Computational Continuum Mechanics. 2014. No. 7. pp. 398-411. DOI: 10.7242/1999-6691/2014.7.4.38
16. Zinyagin A. G. Improvement of the rolling and cooling processes for sheets from pipe steels at 5000 rolling mill. Dissertation… of a Candidate of Technical Sciences. Specialty 05.02.09. Moscow. 2014. 22 p.
17. Sevidov A. E., Muntin A. V., Kolesnikov A. G. Simulation of mechanical wear of work rolls of a wide-strip hot rolling mill using machine learning methods. Chernye metally. 2022. No. 11. pp. 22-27.
18. Jin W., Piereder D., Lenard J. G. A study of the coefficient of friction during hot rolling of a ferritic stainless steel. Lubrication Engineering. 2002. Vol. 58. pp. 29-37.
19. Lenard J., Barbulovic-Nad L. The Coefficient of Friction During Hot Rolling of Low Carbon Steel Strips. Journal of Tribology. 2002. Vol.124. p. 840. DOI: 10.1115/1.1454106
20. Nikitin G. S. Theory of continuous lengthwise rolling. Moscow: MGTU im. Baumana. 2009. 399 p.
21. Harvey Ph. D. Engineering Properties of Steel. American Society for Metals. 1982. p. 527.
22. Kolesnikov A. G., Zinyagin A. G., Muntin A. V., Dunaev V. V. Study of joint hot deformation of nickel alloy and low carbon microalloyed steel in manufacture of heavy plate clad rolled products. CIS Iron and Steel Review. 2022. Vol. 24. pp. 41–48.