Abstract
The paper investigates the effects of friction on the heterogeneity of deformation during rolling through studies using plane strain (2D) and three-dimensional (3D) finite element models designed to simulate the deformation of the embedded pin inserts during rolling. Redundant work due to friction is defined as a path function along the arc of contact. Since deformation during rolling is profoundly influenced by the amount of redundant work, which depends on friction as a path function along the arc of contact, the study has focused especially on methods of representing these frictional effects. The friction studied has been in one of two classes: the coefficient of friction being constant or varying parabolically along the arc of contact. The results show that the values of shear stress and normal pressure along the arc of contact depend upon the friction profile. The magnitude of these frictional effects is revealed by the through thickness variation of the relative pin insert displacement. This displacement changes in the 3D model because transverse spread reduces the amount of displacement along the axial direction. Comparison of the simulations with experimental pin insert shapes shows close agreement between the predicted and experimental results, while revealing the direction of further work needed to provide suitable mechanics models to interpret experimental pin insert data.
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