Study on Asymmetric Rolling of Round Workpieces in Rolls with a Smooth Body

Abstract Deform-3D was applied to develop a mathematical finite element model. The authors performed calculations for the flattening of a round workpiece made of steel grade 80P, 12.1 mm in diameter, reduced to 8.0 mm while varying the roll velocity ratio from 1 to 5. Analytical studies showed that as the roll velocity ratio increased, the rolling force decreased and the accumulated strain along the workpiece cross-section increased. Higher accumulated strain was observed in the region of the workpiece in contact with the faster-rotating roll. The paper presents distribution curves of accumulated strain and stress state fields for the flattening cases under study, demonstrating that a higher velocity ratio leads to an increased share of shear strain and a decrease in tensile stress. Experimental studies on asymmetric velocity flattening of round samples (12.1 mm in diameter) were conducted on rolling mill 400 at the Zhilyaev Laboratory of Mechanics of Gradient Nanomaterials. Hardness measurements across the sample cross-sections showed an increase with the roll velocity ratio. Higher hardness was observed on the surface from the side in contact with the faster-rotating roll.