Modelling the foil rolling process

A review of the main rolling models is conducted to assess their suitability for modelling the foil rolling process. Two such models are Fleck and Johnson's Hertzian model and Fleck, Johnson, Mear and Zhang's Influence Function model. Both of these models are approximated through the use of perturbation methods. Decrease in the computation time resulted when compared with the numerical solution. The Hertzian model was approximated using the ratio of the yield stress of the strip to the plane-strain Young's Modulus of the rolls as the small perturbation parameter. The Influence Function model approximation takes advantage of the solution of the well-known Aerofoil Integral Equation to gain an insight into how the choice of interior boundary points affects the stability of numerical solution of the model's equations. These approximations require less computation than their full models and, in the case of the Hertzian approximation, only introduces a small error in the predictions of roll force roll torque. Hence the Hertzian approximate method is suitable for on-line control. The predictions from the Influence Function approximation underestimates the predictions from the numerical results. Better approximation of the pressure in the plastic reduction regions is the main source of this error.