Prediction of edge cracks and plastic-damage analysis of Mg alloy sheet in rolling

A thermal-mechanical-damage coupled finite elements model was established to investigate temperature changes, edge cracks and rolling force during rolling of magnesium alloy sheet. A cuneal sheet was also adopted to study the influence of reduction on temperature, damage and rolling force. The results show that with increasing the reduction, the rolling force increases, and the temperature of the Mg sheet decreases. Edge cracks occur when the reduction is above 51.6%, with the damage value of above 0.49. The plastic-damage in Mg sheet rolling is a result of hole development, shearing deformation and accumulative plastic strain.