Lawrence Livermore National Laboratory

Ale3D DDC Burn

One of the principal forming processes for aluminum is the hot rolling of ingots into thick slabs and further rolling to form plate and sheet material of various thicknesses. Multiple passes in a reversing rolling mill of a hot slab are required to produce semi-finished aluminum plate. However, the large deformations encountered while rolling may lead to failure modes that result in loss of part or even the entire slab. The formation of defects within the plate, such as edge cracking, delamination, alligatoring (center splitting near the front and rear), and the formation of undesirable rolled end shapes, all lead to product losses.

Processing parameters could be chosen that improve product yield if the slab material response to the hot rolling process were sufficiently well understood. We have worked with a major aluminum manufacturer to develop models that:

  • Predict temperature, stress, strain, and damage evolution of slab material as it evolves through multipass rolling
  • Determine the effect of initial slab shape and rolling pass schedule on fracture and internal product integrity
  • Demonstrate the utility of a numerical model as a forming process optimization tool
  • Heat Transfer

    This movie shows the result of several passes of a hot aluminum slab through cooled steel rollers. The plotted temperature contours show heat transfer from the slab to the rollers, which can be important to stress relaxation rates within the aluminum. The simulation also utilizes ALE3D's capabilities for slide surfaces with friction and thermal contact resistance, in addition to employing sophisticated damage evolution material models.