Analytical model for corrugated rolling of composite plates considering the shear effect

The corrugated rolling process is widely applied in composite plate manufacturing due to its good plate quality and high bonding strength. In accordance with the slab method, a mathematical analytical model of corrugated rolling is presented in this paper. A new and more accurate assumption is adopted, that is, the uneven distribution of shear stress on the vertical side of the slab in the deformation zone is considered. The analytical solution for the roll separating force model is derived by establishing the differential equation for the force balance of the deformation unit within the deformation zone, incorporating the yield condition, and utilizing the geometric and constitutive equations. The determination of the integral constant is based on the boundary condition. In addition, the experimental value and the finite element simulation value are compared with the fluctuating roll separating force obtained by the model to verify the accuracy of the model. The error of the model is within a margin of 2.9 %. In this model, the distributions of particular rolling pressure and particular lateral stress for composite plates and rolls can be conveniently calculated. In addition, different ratio of the friction factors and the ratio of the shear yield stress are discussed in relation to its distribution. The effect of rolling parameters on the fluctuating roll separating force and the position of the lower neutral point are also investigated, such as the reduction ratio, the ratio of the shear yield stress, and the ratio of the friction factor. A fluctuating roll separation force and deformation parameter analytical model can be applied to corrugated rolling to analyze its characteristics. It is important for accurate roll separating force control, as well as for optimizing the rolling process.