Analysis of Sheet Curvature in Asymmetrical Cold Rolling

In asymmetric cold rolling, the workpiece is often bent downwards or upwards. A two-dimensional explicit dynamic finite element model with Arbitrary Lagrangian Eulerian (ALE) adaptive meshing technique has been employed to simulate asymmetrical sheet rolling, in which asymmetrical conditions are here due to different roll radii. To validate the simulation, the results of simulation and experiment are compared. Effects of asymmetry due to roll radii mismatch on the normal and shear distributions and on sheet curvature variations are discussed. An optimum roll radii ratio could be found to produce flat sheet. Trials were conducted to investigate the effectiveness of roll radii mismatch as an approach of sheet curvature control.