Roll pass evaluation for three-dimensional section rolling using a simplified finite element method

A simplified finite element (FE) method for modelling the complex three-dimensional deformation inherent in section rolling is presented. This simplified FE technique has been developed by considering a single slice of material of finite thickness passing through the roll gap, to avoid performing a full three-dimensional finite element analysis. Only one layer of a finite element mesh (consisting of brick elements) is generated on the slice of the process material taken from the three-dimensional workpiece. The slice of material is considered to be compressed using a pair of grooved dies, which have the same profiles as the rolls. In order to make this simplified pseudo-two-dimensional model more realistic, the speed of compression of the grooved dies is modified according to the vertical component of the peripheral roll velocity within the contact zone. Equations have been developed to approximate the roll separation force. This method is applied to perform a pre- and post-rolling FE analysis for the rolling process of a special section produced at British Steel's Skinningrove Works. The roll pass design and the stability of the rolling process are evaluated according to the results obtained from the FE predictions. Comparisons between FE results and experiment are made where possible.