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Metals
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Numerical Simulation of Metal Forming Process
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Numerical Simulation of Metal Forming Process

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: 25 January 2025 | Viewed by 6473

Special Issue Editor

Prof. Dr. Zhenhua Bai

E-Mail Website
Guest Editor
School of Mechanical Engineering, Yanshan University, Qinhuangdao 066004, China
Interests: hot rolling; cold rolling; annealing; leveling; coating; process

Special Issue Information

Dear Colleagues,

As a cornerstone of the industrial sector, steel plays a pivotal role in the development of the national economy. Among its various forms, strip steel accounts for roughly 45% of total steel production and finds extensive applications in aerospace, electronics, automotive, food packaging, construction, and other industries. The production process for strip steel primarily involves hot rolling, cold rolling, annealing, leveling, secondary cold rolling, and coating. Notably, the shaping process for strip steel, which is integral to the entire production cycle, directly influences the final product's shape and falls within the scope of this special edition.In recent years, particularly with the establishment of the "dual-carbon goals," the digital transformation of traditional industries, and the rapid growth of the automotive sector, the digitalization of high-strength, thin-gauge ultra-high-strength strip steel production has become a focal point for steel enterprises. Consequently, innovations in digital forming technologies such as hot rolling, pickling, annealing, leveling, and coating for ultra-high-strength steel are now at the forefront of development for steel companies, research institutions, and universities.Within this special edition, we extend a warm welcome to articles focusing on advanced rolling processes and equipment technologies for strip steel, including hot rolling, cold rolling, leveling, and secondary cold rolling. Of particular interest are studies in intelligent process automation and technological optimization across the entire steel forming process, drawing on metallurgical physics models and deep learning. These advancements hold significant promise in the field of steel rolling technology and have the potential to greatly enhance product quality. In conclusion, the innovation and advancement of strip steel production processes are importance for the steel industry's sustainability.

This special edition serves as a platform for steel enterprises, research institutions, and universities to exchange and share their latest research findings, promoting the industry's progression towards greater intelligence and sustainability.

Prof. Dr. Zhenhua Bai
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • strip steel
  • rolling
  • forming
  • numerical simulation
  • production technology

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Published Papers (4 papers)

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Research

15 pages, 7308 KiB  
Article
Analysis of the Influence of Contact Stress on the Fatigue of AD180 High-Carbon Semi-Steel Roll
by Yaxing Liu, Lixin Liu, Qian Cheng, Haipeng Hou, Zehua Zhang and Zhongkai Ren
Metals 2024, 14(5), 548; https://doi.org/10.3390/met14050548 - 6 May 2024
Cited by 1 | Viewed by 1261
Abstract
In this study, to investigate the problem of contact fatigue and the damage mechanism of an AD180 high-carbon semi-steel roll, rolling contact fatigue tests were conducted using specimens cut from the periphery of a roll ring. These specimens were characterized under different contact [...] Read more.
In this study, to investigate the problem of contact fatigue and the damage mechanism of an AD180 high-carbon semi-steel roll, rolling contact fatigue tests were conducted using specimens cut from the periphery of a roll ring. These specimens were characterized under different contact stresses using SEM, a profile system, an optical microscope, and a Vickers hardness tester. The results indicates that the main forms of fatigue damage of an AD180 high-carbon semi-steel roll are peeling, pitting corrosion, and plowing. Moreover, the surface of the roll exhibits delamination and plastic deformation characteristics under high contact stress. Meanwhile, the size and depth of peeling, as well as the amount of pitting corrosion, increase with the contact stress. Peeling is mainly caused by a crack that originates at the edge of the specimen surface and propagates along the pearlite structure and the interface between pearlite and cementite. High contact stress can lead to an increase in the crack propagation depth and angle, resulting in the formation of larger peeling. Under cyclic loading, the near-surface microstructure of the specimen hardens due to grain refinement and dislocation strengthening, and the depth of the hardened layer increases with the increase in contact stress. When the contact stress reaches 1400 MPa, the near surface structure of the specimen changes from pearlite to troostite. Full article
(This article belongs to the Special Issue Numerical Simulation of Metal Forming Process)
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25 pages, 10767 KiB  
Article
Experimental and Numerical Investigation of Forming Limit Diagrams during Single Point Incremental Forming for Al/Cu Bimetallic Sheets
by Payam Tayebi, Amir Reza Nasirin, Habibolah Akbari and Ramin Hashemi
Metals 2024, 14(2), 214; https://doi.org/10.3390/met14020214 - 9 Feb 2024
Cited by 4 | Viewed by 1328
Abstract
This article investigated the formability of aluminum/copper bimetal sheets during single-point incremental forming. First, the two-layer sheets were produced by the explosive welding process; then, the rolling process was performed with 50% strain on two-layer samples. Considering the importance of examining the mechanical [...] Read more.
This article investigated the formability of aluminum/copper bimetal sheets during single-point incremental forming. First, the two-layer sheets were produced by the explosive welding process; then, the rolling process was performed with 50% strain on two-layer samples. Considering the importance of examining the mechanical and metallurgical properties on the formability of the two-layer samples, the mechanical properties were first examined, including the uniaxial tensile and micro-hardness tests. Then, metallurgical tests were performed, including scanning electron microscopy equipped with energy-dispersive X-ray spectroscopy (SEM-EDX) to investigate the fracture surface and penetration depth and an X-ray diffraction (XRD) test to check the secondary phase particles in the penetration zone of Al and Cu in five different annealing temperature conditions. Considering that the forming limit diagram (FLD) is dependent on the strain path, to study the effect of the strain path, the two-layer samples were formed by three geometries: pyramid, cone, and straight groove. Simulations of FLD by Abaqus software 6.14-4 with four different methods were studied: FLDCRT, effective strain rate (ESR), second derivation of thinning (SDT), and maximum strain rate (MSR). The results showed that the FLDCRT criterion provided a more accurate estimate of the necking time. In the following, the values of the thickness distribution were carried out by experimental and numerical methods, and the results between the methods were in good agreement. Full article
(This article belongs to the Special Issue Numerical Simulation of Metal Forming Process)
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16 pages, 5046 KiB  
Article
Numerical Simulation Research on the Temperature Field and Hot Roll Crown Model of Hot Continuous Rolling Mills
by Zizheng Li, Sahal Ahmed Elmi, Luxuan Liu, Baoliang Yin, Shuang Kuang and Zhenhua Bai
Metals 2024, 14(2), 166; https://doi.org/10.3390/met14020166 - 29 Jan 2024
Cited by 3 | Viewed by 1666
Abstract
Addressing the challenge of roll loss and strip deformation arising from the lack of precise prediction of the roll temperature field in hot tandem rolling mills, this study employs numerical analysis via the finite difference method. Based on the roll temperature field and [...] Read more.
Addressing the challenge of roll loss and strip deformation arising from the lack of precise prediction of the roll temperature field in hot tandem rolling mills, this study employs numerical analysis via the finite difference method. Based on the roll temperature field and hot roll crown model, an intelligent support cooling control system for the roll cooling water of hot rolls is established. This system comprehensively considers the direct impact of specific parameters on the roll temperature field in the intricate context of cooling water dynamics. The study focuses on the cyclic superposition effect of rolling coil quantities on the roll temperature field and the resulting hot roll shape, and theoretical calculations along with simulation analyses were conducted using finite element software. Through the integration of field-measured values, the study achieves accurate predictions of the temperature field and hot roll profile for both work rolls and backup rolls. Full article
(This article belongs to the Special Issue Numerical Simulation of Metal Forming Process)
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17 pages, 8098 KiB  
Article
Research on the Temperature and Thermal Stress of the Roll Quenching Process of Thin Plates
by Jianhui Wang, Xuetong Li, Kesong Yi and Sahal Ahmed Elmi
Metals 2024, 14(1), 83; https://doi.org/10.3390/met14010083 - 10 Jan 2024
Cited by 2 | Viewed by 1521
Abstract
The roll quenching process can be approximated as a high-pressure jet impinging on a high-temperature moving steel plate. The process can greatly improve the strength and overall mechanical properties of the steel plate. However, the cooling uniformity and other factors lead to the [...] Read more.
The roll quenching process can be approximated as a high-pressure jet impinging on a high-temperature moving steel plate. The process can greatly improve the strength and overall mechanical properties of the steel plate. However, the cooling uniformity and other factors lead to the problem of poor plate shape after quenching. It is found that in the roll quenching process, the roller conveyor speed has a large influence on the temperature field and stress field. This paper establishes a roll quenching mechanism model, iterates the convective heat transfer coefficient on the steel plate surface through the inverse heat transfer method, and performs a numerical simulation. Through the numerical simulation of the roll quenching process in the high-pressure zone of the steel plate, the temperature and equivalent force change rule of the transient of each position of the steel plate in the thick direction are obtained. It is found that the plate does not reach its maximum value when it is in the quenching zone, but there is some hysteresis that becomes more pronounced as it gets closer to the core. These findings are valuable for regulating the roll-hardening process and maintaining optimal strip surface quality in industrial production environments. Full article
(This article belongs to the Special Issue Numerical Simulation of Metal Forming Process)
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