Thermo-mechanical modeling of tool and workpiece interface in metal forming process

The deformation of metals, and friction at the tool and workpiece contact region produce large amounts of heat, a part of that heat is conducted towards the tool where it is removed by forced convection. For rolling process, these cooling and heating cycles finally result in a substantial change in the temperature distribution in the roll.; In first part of this work, an attempt is made to study the temperature and heat flux distribution in the roll by considering a non-uniform heat flux at the roll-workpiece interface. Adopting an elemental approach, a methodology has been proposed to model non-uniform heat flux at the interface.; The temperature distribution along with the mechanical load results in roll deformation with large localized stresses. Roll deformation is an important phenomenon that is critical not only for controlling the shape and size of final product but also for minimizing its cost. Under the assumption of an elastic roller and including the heat transfer effects; in the second part of this study the distribution of elastic deformation of the roller has been modeled by using thermo-elastic finite element method. (Abstract shortened by UMI.)...