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Abstract

For the accurate simulation of the rolling process of a wide strip and plates, highly sophisticated algorithms must be developed to couple material flow behavior with the elastic deformation of rolls. A coupling simulation system based on a three-dimensional rigid-plastic finite element method (RPFEM), elastic-plastic finite element method, and influential function method was developed in this study. Calculation of the continuous variable crown (CVC) mill was more complex than that of the normal 4-high rolling mill. According to the point symmetry of the roll gap profile, the CVC curves of work rolls at various shifting positions were equal to various work roll crowns in normal 4-high mills. Thus, an equivalent model that adopts a 1/4 workpiece for calculation using the RPFEM can be employed to analyze metal deformation. Based on the approximate symmetrical distribution of rolling force, the influential function method was applied to solve the overall elastic deformation of all upper rolls. Thus, reliable results concerning profile transfer and tension distribution were obtained by the coupling the strip model alongside routines for elastic roll stack deflection. The results revealed that the equivalent algorithm can reduce the number of iterations by approximately 50% and the computation time by approximately 80% compared with the traditional algorithm.

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