1.6.

9 Rolling of steel plate

Product: Abaqus/Explicit

Elements tested

CPE4R R2D2 C3D8R R3D4

Features tested

Large deformation kinematics, user material, kinematic contact, penalty contact,

friction, analytical rigid surfaces, multiple steps, adiabatic heat generation, adding
contact surfaces and boundary conditions after the first step.

Problem description

This verification problem is similar to the problem described in Rolling of thick

plates,Section 1.3.6 of the Abaqus Example Problems Manual. Here, a two-
dimensional, plane strain case of the rolling problem is considered with a much coarser
mesh for the steel plate. The plate is modeled using plane strain elements (CPE4R) and
8-node brick elements (C3D8R). In the three-dimensional model all out-of-plane
degrees of freedom are prescribed as zero to represent a state of plane strain.

The steel plate has a total thickness of 40 mm and a length of 100 mm. This analysis
simulates the rolling of the plate through two roller stands, each of which achieves a
reduction in the thickness of the plate of 10 mm. The radius of each roller is 50 mm.
The model takes advantage of half-symmetry.

The material is modeled as an elastic, perfectly plastic material with Young's modulus
210 GPa, Poisson's ratio 0.30, yield stress 250 MPa, and density 7500 kg/m3. The two-
dimensional case uses the *USER MATERIAL option, along with user subroutine
VUMAT. This model can be selected by specifying the material name ABQTEST1 on the
*MATERIAL option. The user subroutine has the option to include kinematic
hardening. However, this example problem tests the user material only for the case of
perfect plasticity and verifies the results by comparison with the results obtained with
the standard plasticity model with no hardening (for the three-dimensional case). The
rotating cylinder problem of VUMAT: rotating cylinder,Section 4.1.28, verifies the
hardening case for the user material. The three-dimensional model uses the standard
elastic, perfectly plastic material model specified with the *ELASTIC and *PLASTIC
options. It also tests the adiabatic heat generation capability using the *DYNAMIC,
EXPLICIT, ADIABATIC option, the *SPECIFIC HEAT option, the *EXPANSION
option, and the *INELASTIC HEAT FRACTION option. The initial temperature for all
nodes in the model is 294C. The specific heat for this material is 460.46 Joule/kg/C.

The maximum traction due to friction is assumed to be , or 144.3 MPa.

The contact constraints can be enforced either kinematically or with a penalty method in
Abaqus/Explicit. Kinematic contact gives strict enforcement of the constraints, whereas
penalty contact will allow some penetration. However, the two constraint methods will
usually give nearly the same results for problems that involve plastic deformation (such
as rolling problems), because the contact penetrations with penalty contact will tend to
be small. This is related to the fact that the default penalty stiffness is about 10% of the
elastic stiffness in the elements along the contact interface. When the material yields,
the penalty stiffness will typically be much larger than the effective stiffness of the
material, so the penetrations will be rather insignificant. For problems in which the
material remains elastic (see The Hertz contact problem,Section 1.1.11 of the Abaqus
Benchmarks Manual), the contact penetrations can be significant if the penalty method
is used. While kinematic contact is available only with the contact pair capability,
penalty contact is available with both the contact pair capability and the general contact
capability in Abaqus/Explicit. For this analysis all three approaches to enforcing the
contact constraints are used: kinematic contact with contact pair, penalty contact with
contact pair, and general contact. In the first step of the analyses involving contact pairs,
when only the first roller has a prescribed rotational velocity, only one contact pair is
defined. This contact pair contains the surface of the first roller and the outer surface of
the plate. At the start of the second step, when the plate is just about to reach the second
roller, a second contact pair is introduced that contains the surface of the second roller
and the outer surface of the plate. For the analysis using general contact, the default
internally generated all-inclusive contact surface is referenced using the *CONTACT
INCLUSIONS option; hence, the contact definitions do not need to be modified from
step to step.

The roller speed used for both rollers in this example is 600 rad/s. See Rolling of thick
plates,Section 1.3.6 of the Abaqus Example Problems Manual, for a detailed
discussion of the choice of rolling speeds.

Results and discussion

Figure 1.6.91 shows the original mesh for the two-dimensional model. Figure 1.6.92
shows contours of shear stress at the end of the first step for the two-dimensional model.
Note that the first roller has rotated during the first step, whereas the second roller
remains motionless. Figure 1.6.93 shows contours of shear stress at the end of the
second step for the two-dimensional model. Figure 1.6.94 shows contours of
equivalent plastic strain (SDV5) at the end of the second step for the two-dimensional
model. Since the user subroutine stores the values of equivalent plastic strain as the fifth
state variable, contour plots are generated by the use of the variable SDV5.

Figure 1.6.95 contains a wire frame drawing of the original mesh for the three-
dimensional model. Figure 1.6.96 shows contours of shear stress at the end of the first
step for the three-dimensional model. Figure 1.6.97 shows contours of shear stress at
the end of the second step for the three-dimensional model. Figure 1.6.98 shows
contours of equivalent plastic strain (PEEQ) at the end of the second step for the three-
dimensional model. Figure 1.6.99 shows contours of temperature at the end of the
second step for the three-dimensional model. Note that the use of the ADIABATIC
parameter in this example does not have an effect on the overall solution because none
of the material properties are temperature dependent. It is simply used to calculate the
temperature field obtained from the dissipated plastic work.
Input files

roll2dapa_anl.inp

Two-dimensional kinematic contact analysis using an analytical rigid surface.

roll3dapa_rev_anl.inp

Three-dimensional kinematic contact analysis using an analytical rigid surface of

TYPE=REVOLUTION.

roll3dapa_rev_anl_gcont.inp

Three-dimensional general contact analysis using an analytical rigid surface of

TYPE=REVOLUTION.

roll2dapa.inp

Two-dimensional kinematic contact analysis using rigid elements.

roll3dapa.inp

Three-dimensional kinematic contact analysis using rigid elements.

roll3dapa_gcont.inp

Three-dimensional general contact analysis using rigid elements.

roll3dapa_cyl_anl.inp

Three-dimensional kinematic contact analysis using an analytical rigid surface of

TYPE=CYLINDER.

roll3dapa_cyl_anl_gcont.inp

Three-dimensional general contact analysis using an analytical rigid surface of

TYPE=CYLINDER.

roll2dapa_anl_pnlty.inp

Two-dimensional penalty contact analysis using an analytical rigid surface.

roll3dapa_rev_pnlty.inp

Three-dimensional penalty contact analysis using an analytical rigid surface of

TYPE=REVOLUTION.

Figures
Figure 1.6.91 Undeformed mesh for the two-dimensional model.

Figure 1.6.92 Contours of shear stress at the end of Step 1 for the two-dimensional
model.

Figure 1.6.93 Contours of shear stress at the end of Step 2 for the two-dimensional
model.
Figure 1.6.94 Contours of equivalent plastic strain at the end of Step 2 for the two-
dimensional model.

Figure 1.6.95 Undeformed mesh for the three-dimensional model.

Figure 1.6.96 Contours of shear stress at the end of Step 1 for the three-dimensional
model.

Figure 1.6.97 Contours of shear stress at the end of Step 2 for the three-dimensional
model.
Figure 1.6.98 Contours of equivalent plastic strain at the end of Step 2 for the three-
dimensional model.

Figure 1.6.99 Contours of temperature at the end of Step 2 for the three-dimensional
model.