Finite Element Simulation of Residual Stress Formation in Cold Rolling Process

Rolling is the most important metal deforming operation in industries. The metal is plastically deformed when it is passed through the combination of the rolls. By virtue of plastic deformation and the thermal gradient during cooling of rolled member residual stresses are developed. During, cold rolling residual stresses was evoked. Residual stresses are known as stresses which exist within the material without the employment of the external load. Residual stress cause the stress erosion, brittle fracture, fatigue and buckling. Effect of the residual stresses is favorable or detrimental which is determined by the nature and magnitude of the stresses. Finite element analysis was performed to ascertain the residual stresses in cold rolling with the aid of MSC-MARC software. A 3D finite element model of rolling process was developed to perform the structural analysis. Nature of residual stresses in longitudinal, transverse and along the thickness was studied. The longitudinal residual stress distribution was non-uniform that causes the defects in rolled member. It was found that irregular transverse strain distribution and temperature gradient along the width induces longitudinal residual stresses.