Three-dimensional simulation of flat rolling through a combined finite element–boundary element approach

This paper presents an innovative approach for analysing three-dimensional flat rolling. The proposed approach is based on a solution resulting from the combination of the finite element method with the boundary element method. The finite element method is used to perform the rigid–plastic numerical modelling of the workpiece allowing the estimation of the roll separating force, rolling torque and contact pressure along the surface of the rolls. The boundary element method is applied for computing the elastic deformation of the rolls. The combination of the two numerical methods is made using the finite element solution of the contact pressure along the surface of the rolls to define the boundary conditions to be applied on the elastic analysis of the rolls. The validity of the proposed approach is discussed by comparing the theoretical predictions with experimental data found in the literature.