Effect of Processing Parameters on Edge Cracking in Cold Rolling

Experimental and numerical investigations have been carried out to study the effect of processing parameters on edge cracks in cold rolling process of silicon steels. The onset of edge cracks has been simulated by using finite element method (FEM) based on the Gurson-Tvergaard-Needleman damage model. Factorial design and Taguchi experimental design methods have been proposed to analyze the effects of reduction ratio, tension, work roll diameter, and friction coefficient on the formation of edge cracks. Parametric studies indicated that with the increasing of reduction ratio, friction coefficient, and tension, the crack length increases. A bigger work roll is beneficial to restrict the edge crack growth as well. The rank according to the impact degrees on the crack initiation from high to low is reduction ratio, tension, work roll diameter, and friction coefficient. Meanwhile, the combined effect curve of reduction ratio and tension on crack length was obtained which was validated by the experimental results as well.