A slab method study of strain hardening and friction effects in cold foil rolling process

In the present work, strain hardening and friction models are incorporated in the foil-rolling model developed by earlier researchers. The strain hardening effect is incorporated by means of power law and a more realistic friction model, viz. Wanheim and Bay's model is used. A parametric study has been carried out to show the effect of Wanheim and Bay's friction model and strain hardening on the roll force and roll torque. It is observed that friction model has great influence on qualitative and quantitative predictions of foil-rolling process. Strain hardening also influences the results and needs to be incorporating in a foil-rolling model. Taking average value of flow stress to account for this effect does not work in the case of severe strain-hardening.