Deformation analysis for cold rolling of Al-Cu double layered sheet by physical modeling and finite element method

The deformation characteristics of Al-Cu double layered sheet during rolling with various process parameters were studied by both a physical modeling technique and the finite element method. Physical modeling and the finite element method are complementary, due to their different advantages and limitations. Physical modeling simulates metal forming operations by using a model workpiece under conditions similar to those in actual production. The deformation characteristics of double layered sheet during rolling were also simulated using a commercial finite element code, FORGE™. The effects of process parameters, such as total reduction ratio, initial thickness ratio and differential speed ratio on the rolling characteristics were the primary focus of the investigation. In addition, an analytical model for double layered sheet rolling is also proposed with the use of a force-thickness diagram. From the results, the effect of the process parameters on the rolling of the Al-Cu double layered sheet has been determined.