Finite Element Analysis on Planetary Three-Roll Rolling Advisor Prof.: Y. M. Hwang Student: F. H. Tsai ABSTRACT This paper used three-dimensional finite element code---Deform to analyze the plastic deformation behavior of material at the rolling-gap during planetary 3-roll rolling of rods or bars. The rigid-plastic model was used. The rolls are assumed to be rigid body and the change of temperature during rolling is ignored. The first part was used Deform to simulate the manufactured bars in factory. We analyzed the rolling force, torque and the shape after deformation. These results can offer knowledge for the design of actual rolling mill or pass schedule of the 3-roll rolling processes. The second part was compared with FEM and experiment. The simulation was made with the roll size and shape of a mini-type 3-roll rolling mill. We analyzed the rolling force, torque and the depth of spirals with different inclined angle, offset angle, roll shape and reduction.

This paper is divided into two parts, experiments and finite element simulations. In experiments, the effects of various rolling conditions such as roll rotational speed, reduction, upon entrance and exit axial velocities, entrance and exit rotational speeds, twisting angle of rolled products are investigated. Experiments with roll rotation and planetary rotation are carried out to check the validity of the results obtained by roll rotation only. In finite element simulations, DEFORM 3D is used to simulate planetary three-roll rolling. The rolling torque, the distance between spirals, and the shape are analyzed, and the analytical results are compared with experimental results.