The significant contribution of mathematical modelling both to the understanding and improvement of the cold rolling of flat metal products is indisputable. This survey documents this contribution and claims that mathematical modelling will continue to provide a cost effective quality improvement tool with the finite element approach on fast large-memory computers and the use of the asymptotic approximation offering the best prospects for further major advances.
EdwardsW. J. E.Trends in cold rolled strip production Cold Mill Profile, Flatness and Surface Seminar, AISE, 1992, Pittsburgh, Pennsylvania.
2.
OrowanE.The calculation of roll pressure in hot and cold flat rolling. Proc. Instn Mech. Engrs, 1943, 150, 140–167.
3.
SiebelE.Berichte des Walzwerksausschusses. Vernin deutscher Eisenhuttenleute, 1924, 37.
4.
von KarmanT.Z. für angew. Mathematik und Mechanik, 1925, 5, 139.
5.
HitchcockJ.Roll neck bearings. Report of ASME SpecialResearch Committee on Heavy-Duty Anti-friction Bearings, 1935, Appendix 1.
6.
OrowanE.PascoeK. J.First report of the Rolling-Mill Research Sub-committee, The Iron and Steel Institute, London, 1946, pp. 124–146.
7.
BlandD. R.FordH.The calculation of roll force and torque in cold strip rolling with tensions. Proc. Instn Mech. Engrs, 1948, 159, 144–163.
8.
BlandD. R.FordH.An approximate treatment of the elastic compression of the strip in cold rolling. J. Iron Steel Inst. (Lond.), 1948, 171, 245–249.
9.
AlexanderJ. M.A slipline field for the hot rolling process. (Proc. Instn Mech. Engrs, 1955, 169, 1021–1028).
10.
CollinsI. F.Slip-line field solutions for compression and rolling with slipping friction. Int. J. Mech. Sci., 1969, 11, 971–978.
11.
HartleyP.SturgessC. E. N.LiuC.RoweG. W.Experimental and theoretical studies of workpiece deformation, stress and strain during flat rolling. Int. Mater. Rev., 1989, 34, 19–34.
12.
AlexanderJ. M.On the theory of rolling. Proc. R. Soc. Lond., Ser. A, 1972, 326, 535–563.
13.
VenterR.Abd-RabboA.Modelling of the rolling process–I. Inhomogeneous deformation model. Int. J. Mech. Sci., 1982, 22, 83–92.
14.
VenterR.Abd-RabboA.Modelling of the rolling process–II. Evaluation of the stress distribution in the rolled material. Int. J. Mech. Sci., 1982, 22, 93–98.
15.
SmetR. P.JohnsonR. E.An asymptotic analysis of cold sheet rolling. Trans. ASME, J. Appl. Mech., 1989, 56, 33–39.
16.
JohnsonR. E.SmelserR. E.An asymptotic formulation of shear effects in two dimensional rolling. J. Mater. Proc. Technol., 1992, 34, 311–318.
17.
DomantiS. A.McElwainD. L. S.Two dimensional plane strain rolling: An asymptotic approach to the estimation of inhomogeneous effects. Int. J. Mech. Sci., 1995, 37, 175–196.
18.
JohnsonR. E.Shape forming and lateral spread in sheet rolling. Int. J. Mech. Sci., 1991, 33, 449–469.
19.
ZaharoffT. L.JohnsonR. E.KarabinM. E.Spread in sheet rolling: A comparison using experiments, analytical solutions and numerical techniques. Int. J. Mech. Sci., 1992, 34, 435–442.
20.
KarabinM. E.JohnsonR. E.A comparison of asymptotic and numerical rolling models for quasi-three-dimensional problems. Int. J. Mech. Sci., 1993, 35, 425–439.
21.
KarabinM. E.SmelserR. E.A quasi-three-dimensional analysis of the deformation processing of sheets with applications. Int. J. Mech. Sci., 1990, 32, 375–389.
22.
DomantiS.McElwainD. L. S.MiddletonR. H.Asymptotic approach to the Hill model of spread in rolling. Trans. ASME, J. Engng Mater. Technol., 1995, 117, 75–81.
23.
HillR.A general method of analysis for metal-working processes. J. Mech. Phys. Solids, 1963, 11, 305–326.
24.
LahotiG. D.KobayashiS.On Hill's general method of analysis for metal-working processes. Int. J. Mech. Sci., 1974, 16, 521–540.
25.
KobayashiS.Metal forming and the finite element method–past and future. In Proceedings of the 25th International Conference on Machine Tool Design Research, Birmingham, April 1985, pp. 17–32.
26.
HartleyP.PillingerI.SturgessC. E. N.European developments in simulating forming processes using three-dimensional finite-element analysis. J. Minerals, Metals and Mats, October 1991, 12–15.
27.
MontmitonnetP.BuesslerP.A review on theoretical analyses of rolling in Europe. ISIJ Int., 1991, 31, 525–538.
28.
ZienkiewiczO. C.JainP. C.OnateE.Flow of solids during forming and extrusion: Some aspects of numerical solutions. Int. J. Solids Structs, 1978, 14, 15–38.
29.
DawsonP. R.ThompsonE. G.Finite element analysis of steady-state elasto-visco-plastic flow by the initial stress-rate method. Int. J. Numer. Meth. Engng, 1978, 12, 47–57.
30.
ShimaS.MoriK.OdaT.OsakadaK.Rigid plastic finite element analysis of strip rolling. In Proceedings of the 4th International Conference on Production Engineering, 1980, pp. 82–87.
31.
LiG.KobayashiS.Rigid-plastic finite-element analysis of plane strain rolling. Trans. ASME, J. Engng Industry, 1982, 104, 55–64.
32.
MoriK.OsakadaK.OdaT.Simulation of plane-strain rolling by the rigid-plastic finite element method. Int. J. Mech. Sci., 1982, 24, 519–527.
33.
LiG.KobayashiS.Spread analysis in rolling by the rigid-plastic, finite element method. In Proceedings of the 1st International Conference on Numerical Methods in Industrial Forming Processes (Eds PittmanJ.F.T.WoodR. D.AlexanderJ. M.ZienkiewiczO.C.), 1982, pp. 747–756 (Pineridge Press).
34.
LiG.KobayashiS.Analysis of spread in rolling by the rigid-plastic, finite element method. In Numerical Analysis of Forming Processes (Eds PittmanF. T.ZienkiewiczO. C.WoodR. D.AlexanderJ.M.), 1984, pp. 777–786 (John Wiley, Chichester).
35.
MoriK.OsakadaK.Simulation of three-dimensional deformation in rolling by the finite element method. Int. J. Mech. Sci., 1984, 26, 515–525.
36.
MoriK.OsakadaK.NikaidoH.NaoiT.AburataniY.Finite element simulation of non-steady state deformation in rolling of slab and plate. In Proceedings of the 4th International Steel Rolling Conference, Deauville, 1987, pp. F6.1–F6.8.
37.
HirakawaT.FujitaF.KamataM.YamadaY.Analysis of strip rolling by the finite element method. In Proceedings of the 1st International Conference on Technology of Plasticity, Tokyo, 1984, pp. 1132–1137.
38.
YaritaI.MallettR. L.LeeE. H.Stress and deformation analysis of metal rolling processes. In Proceedings of the 1st International Conference on Technology of Plasticity, Tokyo, 1984, pp. 1126–1131.
39.
LiuC.HartleyP.SturgessC. E. N.RoweG. W.Elastic-plastic finite-element modelling of cold rolling of strip. Int. J. Mech. Sci., 1985, 27(7/8), 531–541.
40.
NagtegaalJ. C.VeldpausF. E.On the implementations of finite strain plasticity equations in a numerical model. In Numerical Analysis of Forming Processes, 1984, pp. 351–371 (John Wiley, Chichester).
41.
LeeE. H.Finite deformation effects in plasticity analysis. In Numerical Analysis of Forming Processes, 1984, pp. 373–386 (John Wiley, Chichester).
42.
McMeekingR. M.RiceJ. R.Finite-element formulations for problems of large elastic plastic deformation. Int. J. Solids Structs, 1975, 11, 601–616.
43.
NagtegaalJ. C.de JongJ. E.Some computational aspects of elastic-plastic large strain analysis. In Computational Methods in Nonlinear Mechanics, 1980, pp. 303–339 (North-Holland, Amsterdam).
44.
DavidC.BertrandC.ChenotJ. L.A transient three dimensional analysis of hot rolling of thick slabs. In Proceedings of Numiform'86 Conference, Gothenburg, 1986, pp. 219–224.
45.
LiuC.HartleyP.SturgessC. E. N.RoweG. W.Analysis of stress and strain distributions in slab rolling using an elastic-plastic finite-element method. In Proceedings of Numiform'86 Conference, Gothenburg, 1986, pp. 231–236.
46.
LiuC.HartleyP.SturgessC. E. N.RoweG. W.Finite-element modelling of deformation and spread in slab rolling. Int. J. Mech. Sci., 1987, 29, 271–283.
47.
LiuC.HartleyP.SturgessC. E. N.RoweG. W.Analysis of stress and strain distributions in slab rolling using an elastic-plastic finite-element method. Int. J. Numer. Meth. Engng, 1988, 25, 55–66.
48.
IguchiT.YaritaI.Three-dimensional analysis of flat rolling by rigid-plastic FEM considering sticking and slipping frictional boundary. J. Iron Steel Inst. (Japan)1991, 31, 559–565.
49.
TozawaY.NakamuraM.IshikawaT.Method of three-dimensional analysis and an applied example–analytical study on the three dimensional deformation in strip rolling I. Int. J. Jap. Soc. Technol. Plast., 1976, 17, 37–44.
50.
TozawaY.IshikawaT.IwataN.Improved three-dimensional analysis for strip rolling–analytical study on three dimensional deformation in strip rolling V. Int. J. Jap. Soc. Technol. Plast., 1982, 23, 1181–1187.
51.
IshikawaT.NakamuraM.TozawaY.The effect of rolling conditions on stress distributions and metal flow–analytical study on three dimensional deformation in strip rolling II. J. Jap. Soc. Technol. Plast., 1976, 17, 980–987.
52.
IshikawaT.NakamuraM.TozawaY.Three-dimensional analysis for strip rolling taking elastic deformation of the rolls into consideration–analytical study on three dimensional deformation in strip rolling III. J. Jap. Soc. Technol. Plast., 1980, 21, 902–908.
53.
IshikawaT.NakamuraM.TozawaY.The application of the three-dimensional analysis for strip rolling to various rolling conditions–analytical study on three dimensional deformation in strip rolling IV. J. Jap. Soc. Technol. Plast., 1980, 22, 250–256.
54.
AtreyaA.LenardJ. G.A study of cold strip rolling. Trans. ASME, J. Engng Mater. Technol.1979, 101, 129–134.
55.
HwuY.LenardJ. G.A finite element study of flat rolling. Trans. ASME, J. Engng Mater. Technol., 1988, 100, 22–27.
56.
GratacosP.MontmitonnetP.FromholzC.ChenotJ. L.A plane-strain elastoplastic finite-element model for cold rolling of thin strip. Int. J. Mech. Sci., 1992, 34, 195–210.
57.
GratacosP.OnnoF.Elastoplastic models for cold rolling, application to temper rolling. In Proceedings of the 6th International Rolling Conference, Dsseldorf, Germany, 1994, pp. 441–445.
58.
KiharaJ.ShenG.AizawaT.Fully coupled elasto-plastic boundary element analysis of work materials with elastically deformed rolls. In 1st International Conference on Modelling of Metal Processes, The Institute of Materials, 1993, pp. 455–461.
59.
YamadaK.OgawaS.AtakaM.Three-dimensional analysis of flat rolling using the rigid plastic finite element method coupled with roll deformation analysis. In Proceedings of the 4th International Conference on Numerical Methods in Industrial Forming Processes, 1992, pp. 755–761.
60.
YanagimotoJ.KiuchiM.Three-dimensional simulation system for coupled elastic/rigid plastic deformation of rolls and workpieces in strip rolling processes. In Proceedings of the 4th International Conference on Numerical Methods in Industrial Forming Processes, 1992, pp. 763–768.
61.
OhS. I.KobayashiS.An approximate method for a three-dimensional analysis of rolling. Int. J. Mech. Sci., 1975, 17, 293–305.
62.
ThompsonE. G.Inclusion of elastic strain rate in the analysis of viscoplastic flow during rolling. Int. J. Mech. Sci., 1982, 24, 655–659.
63.
MoriK.OsakadaK.Simulation of three dimensional rolling by the rigid-plastic finite element method. In Proceedings of the 1st International Conference on Numerical Methods in Industrial Forming Processes (Eds PittmanJ. F. T.WoodR. D.AlexanderJ. M.ZienkiewiczO. C.), 1982, pp. 747–756 (Pineridge Press).
64.
KieferB. V.Three dimensional finite element prediction of material flow and strain distribution in rolled rectangular billets. In Proceedings of the 1st International Conference on Technology of Plasticity, Tokyo, Japan, 1984, pp. 3–7.
65.
DawsonP. R.On modelling of mechanical property changes during flat rolling of aluminium. Int. J. Solids Structs, 1987, 23, 947–968.
66.
LinZ. C.HuangC. J.An analysis of the symmetric rolling of aluminium strips using a three-dimensional elastic-plastic large deformation finite element method. J. Strain Analysis, 1994, 29, 267–276.
67.
FordH.AlexanderJ. M.Rolling hard materials in thin gauges. J. Inst. Metals, 1959, 88, 193–199.
68.
StoneM. D.Rolling of thin strip. Iron and Steel Engineer, February 1953, pp. 61–74.
69.
LossR. J.WeinsteinA. S.ZorowskiC. F.Elastic behaviour in cold rolling at the onset of plasticity. J. Inst. Metals, 1963–4, 92, 104–110.
70.
JortnerD.OsterleJ. F.ZorowskiC. F.An analysis of cold strip rolling. Int. J. Mech. Sci., 1960, 2, 170–194.
71.
GrimbleM. J.FullerM. A.BryantG. F.Solution for the nonlinear functional equation representing the roll gap relationship in a cold mill. Int. J. Numer. Meth. Engng, 1978, 12, 643–663.
72.
FleckN. A.JohnsonK. L.Towards a new theory of cold rolling thin foil. Int. J. Mech. Sci.1987, 29, 507–524.
73.
FleckN. A.JohnsonK. L.MearM. E.Zhang, L. C. Cold rolling of foil. Proc. Instn Mech. Engrs, Part B, Journal of Engineering Manufacture, 1992, 206(B2), 119–131.
74.
YuenW. Y. D.NguyenD. N.MatthewsD. L.Mathematical modelling of the temper rolling process. Presented at the 37th Mechanical Working and Steel Processing Conference, Hamilton, Ontario, 22–25 October 1995.
75.
SutcliffeM. P. F.RaynerP. J.Experimental measurements of load and strip profile in thin strip rolling. Int. J. Mech. Sci. (in press).
76.
DomantiS. A.EdwardsW. J.ThomasP. J.A model for foil and thin strip rolling. Presented at the 1994 AISE Annual Convention, Cleveland, Ohio, 1994.
77.
JohnsonK. L.BentallR. H.The onset of yield in the cold rolling of thin strip. J. Mechanics and Physics of Solids, 1969, 17, 253–264.
78.
ChernovP. P.SoskovetsO. N.ZenchenkoF. I.GorbunkovS. G.MazurV. L.BenderE. A.SkororokhodovV. N.BarminG. Yu.Improvement of schedules for temper rolling of thin metal on two-stand 1400 mill. Steel USSR. 1986, 16, 388–391.
79.
DomantiS. A.EdwardsW. J.Interactions between roll surface and cold rolling parameters. In 2nd International Conference on Modelling of Metal Rolling Processes, The Institute of Materials, London, December 1996, pp. 584–595.
80.
SutcliffeM. P. F.Surface asperity deformation in metal forming processes. Int. J. Mech. Sci., 1988, 30, 847–868.
81.
CurnierA.A theory of friction. Int. J. Solids Structs, 1984, 20, 637–647.
82.
ZmitrowiczA.A thermodynamical model of contact, friction and wear: I. Governing equations. Wear, 1987, 114, 135–168.
83.
WanheimT.BayN.A model for friction in metal forming processes. CIRP Ann., 1978, 27, 189–194.
84.
DerjaguinB. V.ToporovY. P.Influence of adhesion on the sliding and rolling friction. Prog. Surf. Sci., 1994, 45, 317–327.
85.
CarterW. T.A model for friction in metal forming. Trans. ASME, J. Engng Mater. Technol., 1994, 116, 8–13.
86.
HillR.Phil. Mag.1950, 41, 733–744.
87.
FrederiksenN.WanheimT.Development of friction tests for lubrication in model-material experiments. J. Mech. Working Technol., 1985, 12, 261–268.
88.
Al-SalehiF. A. R.FirbankT. C.LancasterP. R.An experimental determination of the roll pressure distribution in cold rolling. Int. J. Mech. Sci., 1973, 15, 693–710.
89.
LenardJ. G.Measurement of friction in cold flat rolling. J. Mater. Shaping Technol., 1991, 9, 171–180.
90.
LenardJ. G.Friction and forward slip in cold strip rolling. Tribology Trans., 1992, 35, 423–428.
91.
JeswietJ.HyahumwaC.A sensor for measuring metal deformation interface forces. J. Mater. Process. Technol., 1993, 39, 251–268.
92.
JeswietJ.CaoX.The effect of aspect ratio upon friction and normal forces in strip rolling. J. Mater. Process. Technol., 1994, 45, 99–104.
93.
JeswietJ.Aspect ratio, friction forces and normal forces in strip rolling. J. Mater. Process. Technol., 1995, 53, 846–856.
94.
StephensonD. A.Friction in cold strip rolling. Wear, 1978, 28, 163–174.
95.
ChengH. S.Plastohydrodynamic lubrication. In ASME Lubrication Division, Spring Meeting, New Orleans, 1966, pp. 69–89.
96.
WilsonW. R. D.WalowitJ. A.An isothermal hydrodynamic lubrication theory for strip rolling with front and back tensions. In IMechE Tribology Convention I, London, 1971, pp. 169–172.
97.
AtkinsA. G.Hydrodynamic lubrication in cold rolling. Int. J. Mech. Sci., 1974, 16, 1–19.
98.
SutcliffeM. P. F.JohnsonK. L.Lubrication in cold strip rolling in the ‘mixed’ regime. Proc. Instn Mech. Engrs, Part B, Journal of Engineering Manufacture, 1990, 204(B4), 249–261.
99.
BuschM. L.BiausserH.BiardG.Le BonA.GrumbachM.Metallurgical and mechanical aspects of temper rolling process. In 4th International Steel Rolling Conference, Deauville, France, 1987, pp. E48.1–E48.7.
100.
SteinhoffK.BÂntenR.RaspW.KoppR.PawelskiO.Development of a model for the simulation of the transfer of surface structure in the temper-rolling process. Steel Res., 1995, 66, 520–525.
101.
MakinouchiA.IkeH.MurakawaM.KogaN.CiupikL. F.Finite element analysis of flattening of surface asperities by rigid dies in metal working processes. In Proceedings of the 2nd International Conference on Technology of Plasticity, Stuttgart, 1987, pp. 59–66.
102.
WilsonW. R. D.SheuS.Real area of contact and boundary friction in metal forming. Int. J. Mech. Sci., 1988, 30, 475–489.
103.
WistreichJ. G.Control of strip shape during cold rolling. J.Iron Steel Inst., 1968, 206, 1203–1206.
104.
ShohetK. N.TownsendN. A.Roll bending methods in crown control in four-high plate mills. J. Iron Steel Inst., 1968, 206, 1088–1098.
105.
SabatiniB.YeomansK. A.An algebra of strip shape and its application to mill scheduling. J. Iron Steel Inst., 1968, 206, 1207–1213.
106.
BryantG. F.Automation of tandem mills. The Iron and Steel Institute, Publication 160, 1973.
107.
SpoonerP. D.BryantG. F.Analysis of shape and discussion of problems of scheduling, setup and shape control. The Metals Society Shape Conference, Chester, 1976, pp. 19–29.
108.
DomantiS. A.McElwainD. L. S.MiddletonR. H.EdwardsW. J.The decay of stresses induced by flat rolling of metal strip. Int. J. Mech. Sci., 1993, 35, 897–907.
109.
CoupezT.Automatic remeshing in three-dimensional moving mesh finite element analysis of industrial forming. In Proceedings of Numiform'95 Conference, Ithaca, New York, 1995, pp. 407–412.
110.
CoupezT.ChenotJ. L.Mesh topology for mesh generation problems–application to three-dimensional remeshing. In Proceedings of Numiform'92 Conference, Valbonne, France, 1992, pp. 237–242.
111.
ThomasR.KoppR.DebyeJ.LausbergL.SchniedersR.OberschelpW.Optimization of metal forming processes, refinement and optimization of quadrilateral element meshes. In Proceedings of the 4th International Conference on Numerical Methods in Industrial Forming Processes, Valbonne, France, 1992, pp. 307–312.
112.
ChenotJ. L.Finite element modelling of metal forming: Recent achievements and future challenges. In Proceedings of the 3rd International Conference on Computational Plasticity, Barcelona, Spain, 1992, pp. 1019–1036.