Flat rolling of plate using Abaqus and metal forming book

Project Overview

In this Abaqus project, the flat rolling process of a metal plate is simulated using the Abaqus software.

The project demonstrates how a plate can be modeled and analyzed during the rolling process, allowing the deformation of the plate to be investigated as it passes through the rolling setup.

This tutorial provides a step-by-step explanation of the modeling procedure in Abaqus and shows how the results of the metal forming simulation can be evaluated.

Calculation and Comparison of Rolling Force

The main objective of this training is to determine the force applied to the roller during the flat rolling process using two different approaches. First, the rolling force is calculated using the analytical solution presented in the Metal Forming Book. Then, the same force is obtained from the Abaqus simulation. Finally, the results obtained from the analytical solution and Abaqus are compared to evaluate the agreement between the two approaches.

Metal Forming Analysis

Metal forming simulations require appropriate modeling of the interaction between the workpiece and the forming tools. In this project, the Abaqus model is used to demonstrate the numerical analysis of the rolling process.

The deformation of the plate can be examined during and after the rolling operation using the Abaqus visualization module.

2D Plane Strain Model

The problem is modeled using a 2D plane strain approach in Abaqus. Although the numerical model is defined as a two-dimensional plane strain model, the simulation can be visualized in a three-dimensional form to provide a clearer representation of the flat rolling process.

Rolling Force Results

As shown in the results, the force obtained from the analytical solution based on the Metal Forming Book is 159,000 N, while the force obtained from the Abaqus simulation is 177,000 N.

The difference between the result obtained from Abaqus and the analytical solution is approximately 11%. This comparison demonstrates a good agreement between the numerical simulation and the analytical solution.

Deformation of the plate during the rolling process

The simulation results provide information about the deformation of the plate during the rolling process. The results can be visualized in Abaqus to better understand the behavior of the workpiece during metal forming.

What You Will Learn

• How to model a flat rolling process in Abaqus.
• How to create the workpiece and rolling setup.
• How to define the required interactions between the model components.
• How to perform a metal forming analysis in Abaqus.
• How to investigate plastic deformation of the plate.
• How to visualize the deformation during the rolling process.
• How to examine and process the numerical results.

Key Features

• Flat rolling simulation.
• Metal forming analysis.
• Step-by-step Abaqus tutorial.
• Abaqus CAE file.
• Abaqus INP file.
• Excel results file.
• Metal forming PDF book.