Computing Sheet Rolling Instabilities with a Shell Finite Element Model

A. Cometa*, H. J.M. Geijselaers, J. Havinga, A. H. van den Boogaard

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contributionAcademicpeer-review


In this paper a novel model for 3D finite element sheet metal rolling calculations is presented. A global model which represents the behavior and stress state of the strip outside the roll bite is coupled to a local model which represents in detail the mechanics of deformation within the roll bite. Shell finite elements are used for the global model of the rolled sheet, while 2D plane strain elements are used for the local model of the strip and the roll. The coupling is made via an equivalent roll bite model, incorporated into the shell model to represent the physics of the roll bite. The rolling velocity, the zero out-of-plane position and the thickness strain are enforced at the roll line via a set of constraint equations. The amount of prescribed thickness reduction is determined based on the local tensions and friction coefficient. A metamodel which provides the relation between these conditions and the local thinning is obtained from 2D off-line rolling calculations. The proposed model can be used instead of a full 3D rolling model, as it is computationally less expensive, especially for thin strip rolling simulations. It is shown how the developed model can be applied to analyze instability phenomena in cold rolling processes, specifically strip buckling due to disruptions in the process conditions.

Original languageEnglish
Title of host publicationProceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity - ICTP 2023 - Volume 2
EditorsKatia Mocellin, Pierre-Olivier Bouchard, Régis Bigot, Tudor Balan
Number of pages12
ISBN (Electronic)978-3-031-40920-2
ISBN (Print)978-3-031-40919-6
Publication statusE-pub ahead of print/First online - 20 Aug 2023
Event14th International Conference on Technology of Plasticity, ICTP 2023 - Mandelieu-La Napoule Congress and Exhibition Center, Mandelieu-La Napoule, France
Duration: 24 Sept 202329 Sept 2023
Conference number: 14

Publication series

NameLecture Notes in Mechanical Engineering
ISSN (Print)2195-4356
ISSN (Electronic)2195-4364


Conference14th International Conference on Technology of Plasticity, ICTP 2023
Abbreviated titleICTP 2023
CityMandelieu-La Napoule


  • Flatness defects
  • Steel sheets
  • Thin strip rolling
  • NLA


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