ALE3D Rolling Simulations [electronic resource].
- Washington, D.C. : United States. Dept. of Energy, 2006.
Oak Ridge, Tenn. : Distributed by the Office of Scientific and Technical Information, U.S. Dept. of Energy.
- Physical Description:
- PDF-file: 24 pages; size: 1 Mbytes
- Additional Creators:
- Lawrence Berkeley National Laboratory, United States. Department of Energy, and United States. Department of Energy. Office of Scientific and Technical Information
- Restrictions on Access:
- Free-to-read Unrestricted online access
- Hot rolling is a problem involving large deformations during the process of turning an ingot into a thin sheet. As a result of the large deformations inherent in the process, significant amounts of energy are put into the ingot mechanically, most of which results in heat generation. Therefore, in order to predict the results of rolling both the mechanical and the thermal factors must accurately represent the real conditions. The factors which must be properly tuned include interface friction, mass scaling to decrease computation times, heat transfer at the interface, convective heat transfer from the ingot, and convective heat transfer from the roll. Since these parameters are generally not measurable the correct values must be derived by tuning the parameters so that solutions match some other measurable result. The interface friction will be tuned using an ALE3D input deck which has been set up to output the torque applied to the roll during the pass. The friction coefficient will be adjusted so that the computed torque matches the measured value. The various heat transfer coefficients are dependent on each other, and are tuned based on measured roll surface temperatures, ingot exit temperatures, and the energy input through the mechanical deformation of the ingot. The heat transfer coefficient at the interface has been found to be approximately 1.25 x 10⁵ W/m²K, based on estimates of how much heat can be taken from the roll surface by coolant and matching a roll surface temperature. The convection coefficient on the ingot surface has been assumed to be 100 W/m²K, on the high end for convection to air. However, this convection coefficient is low enough that the ingot should cool uniformly through its thickness as it would with a lower convection coefficient. Also necessary in accurate modeling is a good description of material behavior. In order to aid the development of an accurate material model an ALE3D input deck which simulates compression tests with temperature gradients has been developed. The model output engineering stress-strain curves which can be compared to the experimentally collected data. Also, comparisons of the deformed shapes can be made. The model has been tuned using MTS parameters for AA 5182 and will be ready for use when parameters for AA 2024 are experimentally developed. Currently, more work is needed to properly tune all the model parameters. A parameterized three dimensional geometry and mesh has been created so that once the parameters are tuned the transition to three dimensional simulations should be quick.
- Report Numbers:
- E 1.99:ucrl-tr-223365
- Other Subject(s):
- Published through SciTech Connect.
- Funding Information:
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