Finite Element Modeling of Roll Wear during Cold Asymmetric Sheet Rolling of Aluminum Alloy 5083

Since the main purpose of asymmetrical rolling is to impose high shear strains on the sheet, in order to obtain ultrafine grain structure, the friction between the rolls and the sheet has to be kept relatively high. This means that asymmetric rolling is performed with dry rolls. The paper presents a numerical analysis of the roll wear during asymmetric cold rolling of 5083 aluminum alloy. The finite element simulation was used to calculate the amount of roll wear by Usui’s equation. FEM simulations were carried out with using software DEFORM 2D. The influence of the friction coefficient on the roll wear and the material flow was discussed. The sliding velocity, interface pressure and temperature were used to calculate the roll wear. The results of simulation can be used to optimize the asymmetric rolling process to improve surface quality of aluminum sheets.