3D FEM modelling and experimental investigations of Al-Cu bimetallic bars rolling process in modified grooves

The paper presents the results of the numerical modelling and experimental tests of Al–Cu bimetallic bars groove rolling process. A bimetallic feedstock was manufactured using an explosive cladding method. The feedstocks were round bars with diameter of 22 mm and a cladding layer share of 15 and 30 %. As a result of rolling in 4 passes bars of a diameter of 16 mm were obtained. By applying the multi‐radial modified grooves to the rolling of Al–Cu bimetallic bars the stability of the rolling process was improved, whereby, finished bars with a uniform cladding layer distribution along the core and small diameter dimensional deviations were obtained. Forge2011®, a FEM‐relying software program, was employed for the theoretical examinations.