An advanced computer aided simulation technique for three-dimensional rolling processes, named complex element method (CEM), has been developed. It is based on functional combination of the rigid-plastic FEM and the slab method. It has capability to analyze various rolling processes very effectively and economically and calculate strain, stress and contact pressure distributions, rolling load, rolling torque and dimension of rolled product.
In this paper, firstly, mathematical formulation of the extended CEM is explained, where non-uniformity of longitudinal velocity distribution on every cross section of workpiece is taken into consideration. Then it is applied to the universal rolling processes of H-beams. Calculated results on rolling load, rolling torque, induced back tension and compression, strain distribution in workpiece and geometry of rolled product are found reasonable and acceptable. It is concluded that the extended CEM can be an effective tool for the design and diagnosis of roll profiles and pass-schedules.
