On the modeling of rolling: a special look at edge cracking

Large amounts of rolled sheet and strip production are reworked yearly due to defects that include edge cracking. In an effort to understand the mechanism and causes of edge cracking during rolling a finite element model was used. These models utilized the commercial package ABAQUS and its built in automatic mass scaling scheme. A subroutine (VUMAT) was developed to provide for rate dependent elasto-viscoplastic response and evolution of damage. Results of the model and damage are presented for differing lay-on temperatures, width to thickness ratios, edge shapes, frictional values, and asymmetric rolling. In addition, tips on modeling rolling and secondary tensile stresses are discussed