Development of Quasi-Two-Dimensional FEM Model for Form Rolling Analysis

Abstract

A form rolling analysis model generally needs massive elements for solving large plastic deformation of three- dimensional problems with sufficient accuracy. We have developed a unique and compact analysis model. The smallangle-cut model can be a small model but it will not be sufficient to analyze stress concentration near the contact surface between the roll and the blank. We have developed a compact model composed of small-angle one-layer solid elements given a certain angular velocity field with oblique roll contact. The computation time using this model was only about 1/2000 that when using the full-size model. This model will shorten both the model generation period and the span of design change leading to refined performances of the product prepared with the form rolling process.