Simulation of the Deformation Zone and Stress-Strain State during Screw Rolling of Billets from Hard-Deformed Alloy

Computer simulation of the processes of three- and four-roll helical rolling of a workpiece from a hard-to-deform alloy using the QForm finite element analysis computing environment was carried out. The rolling processes were simulated with equal pinch reduction and equal pinch diameters of the rolls of a three-roll mill and the main rolls of a four-roll mill. Based on the simulation results, the lengths of the actual deformation zone, the geometric deformation zone, and the external zones for both rolling schemes were compared. It was found that in the volume of the workpiece the accumulated strain is more evenly distributed during four-roll rolling and the spread of the values of the accumulated strain between the center and the surface of the workpiece is smaller. The average value of the effective stress in the cross section of the workpiece in pinch at a steady stage is less in four-roll rolling, and the distribution of effective stress values in the studied section is more uniform.