Finite Element Analysis And Experimental Study Of Aluminum Rolling

The main alloy element of 4XXX alumiunm alloy is silicon, which has many advantages, for: high-silicon aluminum alloy, low melting point, good mobility, easy fill shrink, and final product without Brittleness. So the addition materials are producted with this kind Al alloy, for example: brazing sheet, welding rod and wire and so on. High-silicon aluminum alloy 4004 is used more widely. While the features of 4004 alloy is that porosity defect is generated easy, which effects directly on product quality and service safety, and this defect is found in the normal process lead to it is difficult to ensure processing quality. This problem can not to be solved by the current domestic technology. In this thesis, finite element software ABAQUS was utilized to simulate the rolling process of Al alloy. The variation law of porosity defect was explored when different process parameters(reduction, rolling speed, rolling passes) were changed, and the stress and strain of porosity was showed intuitve, so the trend of producting rolling edge crack and strip breakage was judged. Finally, a reasonable program of rolling process was given, the technical problem of porosity lead to decreasing finished product rate was solved. The main research work was as follows:1. The spin injection refining technology was utilized, the process parameters were optimizated through reaserching the influence law of various of factors, the aim is to finding an optimal process scheme, and increasing the rate of degassing. The mechanical properties of 4004 alloy (tensile strength, elongation) were improved after the refining.2. The finite element models (FEM) of roller and rolling with porosity defect were established by mean of finite element analytic software ABAQUS, the dynamic finite element simulation of aluminum rolling process was achieved, the parameter models were set, the simulation and calculation program was given according to practical experience, and reduction, rolling speed and rolling pass were reasonable arranged.3. Analysis of the reduction simulation program. On the premise of rolling speed and rolling pass and so on were unchanged setting the reduction was 0.3mm and 1.0mm, the changement of the stress and strain of different positions of porosity, and the evolution law of porosity defect were simulated and analized, the possibility of producting rolling edge crack and strip breakage was judged.4. Analysis of the simulation program of rolling speed and rolling pass, the same of other process parameters were unchanged, rolling speed was set to 2.0m/s and 5.0m/s, and rolling pass was set to one pass and two passes. the changement of the stress and strain of different positions of porosity, and the evolution law of porosity defect were simulated and analized separately after changing every rolling parameters, finally, the possibility of producting rolling edge crack and strip breakage is judged.According to the simulation results: under the condition of changing different rolling process parameters, the distribution law of rolling stress and strain during aluminum rolling process, and the fluctuation of the stress and strain of porosity defect which locate roller surface and center are researched. The relationship of simulation parameters and the porosity evolute into edge crack and strip breakage is obtained, which can guid and help to improving the producting processes.