Quasi Two Dimensional FEM Model for Form Rolling Analysis and Its Application with LS-DYNA

Abstract

A form rolling analysis model generally needs massive elements solving large plastic deformation of three dimensional problems with sufficient accuracy. We have developed a unique and compact analysis model. A small angle cut model can be a small size model but it will not be enough to analyze precise phenomena near the contact surface between the roller and the blank. We have developed a compact model composed of small angle one-layer solid elements given a certain angular velocity field with oblique roll contact. The computation time of the model indicated only about 1/2000 compared with that of full size model. This model will shorten both the model generation period and the span of the design change refining the performances of the product with form rolling process. We tried this method on an example to understand the precise material deformation history under the large deformation occurred according as the rolling deformation on a certain aluminum circular plate. In this trial we utilized the function “Component Analysis” of LS-DYNA(Crash and Structure Analysis software). This function is used for precise investigations to material deformations in some narrow compartments of the components. We aimed to survey the material structure precise changes under the working tool.