3D rigid-plastic finite element analysis for skew rolling process of the stepped part

Based on rigid-plastic finite element method, a skew rolling process of stepped part is simulated. Considering node-saving and effective remeshing, the tetrahedron solid elements are used to discrete workpiece. The workpiece material adopts rigid-plastic model, where the flow stress is function of effective strain, effective strain rate and temperature. The thermomechanical coupling is considered in the simulation. To model the spinning workpiece undergoing plastic deformation, a novel solution is presented and applied in this paper. The stress state in the workpiece and forming characteristic of skew rolling are analyzed. The forming load, including roller torque and forces in three directions are predicted. The above analyses are helpful to understanding of forming mechanisms and improving of process and die design.