Understanding the bending behavior and through-thickness strain distribution during asymmetrical rolling of high-strength aluminium alloy plates

The asymmetric rolling (ASR) process is highly desired to improve the through-thickness deformation/strain uniformity by introducing additional shear strains for uniform through-thickness microstructures and mechanical properties of metallic/alloy plates. In this study, the bending behavior and mechanism during the ASR processing of high-strength AA7050 aluminium alloy plates were simulated along with rolling trials. It shows that the plate will bend upward (toward slower roll) at larger speed ratios and smaller thickness reductions but downward (toward faster roll) at smaller speed ratios and larger thickness reductions. The ASR processing can increase the central equivalent plastic strains and decrease the surface-to-center strain gradient compared with that caused by the conventional symmetric rolling. The high strain rate bands (HSRBs) as key plastic strain accumulation regions are intimately connected with the post-rolling equivalent plastic strain distribution and the outgoing curvature. Especially, when the HSRB approaches the plate upper surface near the end of the deformation zone, normally at larger thickness reductions, a downward bending occurs despite that the lower roll rotates faster, and vice versa. The through-thickness HSRB induced by the ASR processing is considered to mainly enhancing the equivalent plastic strain homogeneity. The formation and interactive mechanisms of the HSRBs and their connection with the bending behavior during the ASR processing were discussed.