Effect of a Deformable Roller on Residual Stress Distribution for Elastic-Plastic Flat Plate Rolling under Plane Strain Conditions

In this paper, the differences of the residual stresses due to rolling in a finite elastic-plastic plate by rigid and elastic deformable rollers at very high rolling loads are investigated by two-dimensional plane strain finite element analyses using ABAQUS. In the finite element analyses, the rollers are modeled both as rigid and linear elastic, and have frictionless contact with the elastic-plastic finite plate. The plate material is modeled as an elastic-plastic power-law strain hardening material with a non-linear kinematic hardening rule for loading and unloading. Two new numerical schemes are developed to represent the elastic roller to model the indentation and rolling. The results of the contact pressure and subsurface stress distributions from the two numerical schemes are almost identical. For both roller models, the computational results show that the contact pressure and subsurface stress distributions in the elastic-plastic plate are similar for both indentation and rolling at high rolling loads with extensive plastic deformation. The computational results also indicate that the residual stresses after rolling are nearly the same for both roller models. The computational results suggest that the rigid roller model can be used to obtain the residual stresses in rolling simulations at very high rolling loads without sacrificing the accuracy.