Analytical model of flat rolling force for corrugated composite sheet

IF 7.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

International Journal of Mechanical Sciences Pub Date : 2025-04-30 DOI:10.1016/j.ijmecsci.2025.110327

Yuanming Liu , Jun Su , Zhenhua Wang , Dongping He , Tao Wang , Qingxue Huang

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Abstract

This study presents an analytical model for calculating flat rolling force in corrugated-flat rolling (CFR) using the slab method. The model fully accounts for the shear effect on the vertical sides of the differential element within the deformation zone. By formulating the static equilibrium differential equation and incorporating boundary conditions and yield criteria, key deformation parameters are determined. Experimental validation through flat rolling tests and numerical simulations of Cu/Al corrugated composite sheets confirms the model’s accuracy, with deviations of 0.85% and 2.32% between simulated, measured, and calculated rolling forces. The model is further applied to analyze rolling pressure distributions under two contact states, exploring the effects of shear yield stress and friction factor ratios on rolling pressure and specific horizontal stress. Additionally, the influence of reduction rates, shear yield stress ratios, and friction factor ratios on rolling force and the bottom roll neutral point position is systematically examined. The proposed model provides a reliable theoretical foundation for understanding mechanical behavior in flat rolling, optimizing process parameters, improving composite sheet quality, and advancing CFR technology.

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波纹复合薄板轧制力解析模型

提出了一种用板坯法计算瓦楞扁轧扁轧制力的解析模型。该模型充分考虑了变形区内差速单元竖向两侧的剪切作用。通过建立静力平衡微分方程，结合边界条件和屈服准则，确定了关键变形参数。通过平轧试验和Cu/Al波纹复合板的数值模拟验证了模型的准确性，模拟轧制力、实测轧制力和计算轧制力的偏差分别为0.85%和2.32%。进一步应用该模型分析了两种接触状态下的轧制压力分布，探讨了剪切屈服应力和摩擦系数比对轧制压力和比水平应力的影响。此外，系统地考察了压下率、剪切屈服应力比和摩擦系数比对轧制力和辊底中性点位置的影响。该模型为理解扁轧力学行为、优化工艺参数、提高复合板材质量、推进CFR技术发展提供了可靠的理论基础。

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来源期刊

International Journal of Mechanical Sciences 工程技术-工程：机械

CiteScore

12.80

自引率

17.80%

发文量

769

审稿时长

19 days

期刊介绍： The International Journal of Mechanical Sciences (IJMS) serves as a global platform for the publication and dissemination of original research that contributes to a deeper scientific understanding of the fundamental disciplines within mechanical, civil, and material engineering. The primary focus of IJMS is to showcase innovative and ground-breaking work that utilizes analytical and computational modeling techniques, such as Finite Element Method (FEM), Boundary Element Method (BEM), and mesh-free methods, among others. These modeling methods are applied to diverse fields including rigid-body mechanics (e.g., dynamics, vibration, stability), structural mechanics, metal forming, advanced materials (e.g., metals, composites, cellular, smart) behavior and applications, impact mechanics, strain localization, and other nonlinear effects (e.g., large deflections, plasticity, fracture). Additionally, IJMS covers the realms of fluid mechanics (both external and internal flows), tribology, thermodynamics, and materials processing. These subjects collectively form the core of the journal's content. In summary, IJMS provides a prestigious platform for researchers to present their original contributions, shedding light on analytical and computational modeling methods in various areas of mechanical engineering, as well as exploring the behavior and application of advanced materials, fluid mechanics, thermodynamics, and materials processing.