What is Rolling Simulation with CAE? – Benefits & Case Studies

By utilizing CAE (Computer-Aided Engineering) in rolling processes, you can predict deformation, fracture conditions, heat cracks, and hardness throughout the process, thereby preventing potential defects.
In this article, we will introduce Rolling, discuss the benefits of CAE analysis, and share case studies.

What is Rolling?

Rolling is a metal forming method that gradually and repeatedly applies local plastic deformation through the rotation of materials or tools, such as sheet metals, pipes, and bars, to achieve the desired shape.

Advantages:

• Rolling requires lower processing forces and can be performed with simpler tools and smaller equipment compared to pressing.
• It can form undercut shapes, which are difficult or impossible to achieve with pressing.

Disadvantages:

• Rolling has longer processing times, resulting in lower productivity.

These are common types of rolling:

• Cross Rolling
• Ring Rolling
• Shape Rolling
• Orbital Forging
• Roll Forging
• Screw Threading
• Spinning
• Back Rolling

Benefits of CAE Analysis for Rolling

CAE analysis for rolling process enables you to predict deformation, micro-structural changes, heat cracks, and hardness throughout the process. This allows you to optimize heating and cooling conditions, prevent potential defects in subsequent processes, and reduce production costs.

Examples of Rolling Simulations with CAE Solution

Now, we will introduce you examples of simulations using the CAE software DEFORM.

Case Studies (Click on the image to visit the 3D animation page)

Here are case studies of rolling, ring rolling, spinning, and cross-rolling simulations using DEFORM.
The differences in forming conditions, such as rolling velocity and temperature, result in variations in the final shapes.

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  Orbital Forging Simulation: This is a case study of orbital forging simulation. DEFORM supports simulations of complex die motions, including parallel shifts and multi-axial rotations.

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  Roll Forging Simulation: This is a case study of roll forging simulation. DEFORM supports various roll forming processes, including rolling and roll forming.

   

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  Shape Rolling Simulation: This is a case study of a rolling process simulation. DEFORM evaluates temperature changes and strain during the process.

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  Back Rolling Simulation: This is a simulation of the rolling process for different materials. DEFORM supports simulations involving multiple deformable objects.

   

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  Cross Rolling Simulation: This is a simulation of cross-rolling. This analysis visualizes contact conditions and strain distribution during the forming process.

   

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  Screw Threading Simulation: This is a case study of screw threading simulation. The strain distribution is displayed in the bottom right of the screen.

   

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  Plastic Strain Visualization (Ring Rolling): The simulation allows you to observe the red contour, which represents plastic strain. DEFORM uses the ALE method to shorten simulation time.

   

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  Die Filling Observation (Ring Rolling): You can see how the material fills the die when the ring is rolled into its final shape.

   

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  Dedicated Solver and Pre-Processor (Ring Rolling): DEFORM features a dedicated solver and pre-processor specifically for ring rolling, enabling high-precision and short-time simulations.

   

Conclusion

Thank you for reading!
By utilizing CAE, it is possible to prevent defects in advance, while also reducing costs and shortening lead times. The CAE software DEFORM offers a wide range of features to support designers, including capabilities for additional processes, data analysis, experimental design modules, and an optimization modules.
If you have any questions or concerns regarding product design or manufacturing, please feel free to contact us.