Constitutive flow behaviour and finite element simulation of hot rolling of SiCp/2009Al composite

• 17vol.%SiCp/2009Al composite was subjected to hot-rolling simulation.
• Material constants in the Arrhenius-type constitutive equations were obtained.
• Hot rolling process was simulated with a 3-D thermo-mechanical coupled FEM.
• Initiation and propagation of edge cracks were studied via the GTN damage model.

The material parameters of 17vol.%SiCp/2009Al composite in the Arrhenius-type constitutive equations were calculated using experimental data from hot compression tests. The constitutive equation was then implemented into the finite element software, ABAQUS/Explicit, to calculate the stress, deformation and edge damage in the hot rolling process. The initiation and propagation of edge cracks under the hot rolling condition were studied via the Gurson–Tvergaard–Needleman (GTN) damage model. The influence of the thickness reduction on the strip damage was assessed. The results indicate that the high tensile stress at the edge of the strip causes crack initiation and propagation, and the total reduction has a significant effect on the damage in the hot rolling of the SiCp/2009Al composites. When the reduction is less than 20%, no crack initiates and the damage occurs on the strip surface. With increase of the total reduction to 25% and larger, edge cracks occur and increase gradually. The distribution and direction of edge cracks are closely correlated with the stress components. The hot rolling experiments on 17vol.%SiCp/2009Al composite were conducted to evaluate the simulation results, and it is indicated that the finite element calculation results agreed well with the experimental results. This indicates that the finite element analysis is able to successfully simulate the rolling process and provide important information for the process optimization.

3D finite element model. Damage morphology of SiCp/2009Al composite. Figure optionsDownload as PowerPoint slide