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The rolling of rods with slitting of the strip calls for the use of special mathematical models that would allow for the separating of metal. A theoretical analysis of the effect of the gap of slitting rollers on the process of band slitting during the rolling of 20 mm and 16 mm-diameter ribbed rods rolled according to the two-strand technology was carried out within this study. For the numerical modeling of strip slitting the Forge3® computer program was applied. The strip slitting in the simulation is implemented by the algorithm of removing elements in which the critical value of the normalized Cockroft - Latham criterion has been exceeded. To determine the value of the criterion the inverse method was applied. Distance between a point, where crack begins, and point of contact metal with the slitting rollers was the parameter for analysis. Power and rolling torque during slit rolling were presented. Distribution and change of the stress in strand while slitting were presented. © 2007 American Institute of Physics [ABSTRACT FROM AUTHOR]

A solution to mesh distortion and subsequent breakdown in solution procedure in the finite element analysis of multi-stand rolling is presented in this work. Simple cubic spline fits are applied on the deformed outer surface of the rolled material to smoothen the geometry due to distortion from the deformation in the previous stands. A mesh re-zoning algorithm found in the literature is applied while retaining the original number of elements in the new mesh. The appropriate boundary conditions are applied efficiently with the use of a linear interpolation. The approach is illustrated for the multi-stand rolling of a nickel-base super alloy bar of circular cross-section. An in-house finite element program for steady state rolling, based on ALE technique was employed for the current work. The results show that the mesh re-zoning algorithm eliminates the numerical issues associated with the mesh distortion. The predicted results for the final shape are also found to be in good agreement with the experimental data. © 2007 American Institute of Physics [ABSTRACT FROM AUTHOR]