Simulation of Square-to-Oval Single Pass Rolling Using a Computationally Effective Finite and Slab Element Method

This paper presents details of a quasi three-dimensional finite element formulation for shape rolling, TASKS. This formulation uses a mix of two-dimensional finite element and slab element techniques to solve a generalized plane strain problem. Consequently, quasi steady state metal forming problems such as rolling of shapes can be analyzed with minimal computational effort. To verify the capability of the formulation square-to-round single pass rolling is simulated by TASKS and results compared with a fully three-dimensional simulation reported in literature. The results indicate reasonable agreement in roll forces, torques, and effective strain distributions during rolling. However, due to the generalized plane strain assumptions, nonhomogenieties in the rolling direction cannot be simulated. The large computational economy realized via TASKS gives this formulation the power to analyze roll pass designs with reasonable computational resources.