EXPERIMENTAL AND FINITE ELEMENT ANALYSIS OF RESIDUAL STRESSES INDUCED DURING HOT ROLLING IN C45 STEEL GRADE by Balraj Singh
Rolling is one of the most important metal deforming operation in industry. The metal is plastically
deformed when it is passed through the combination of the rolls. By virtue of plastic deformation and the thermal gradient during cooling of rolled member residual stresses are developed. Residual stress cause the stress erosion, brittle fracture, fatigue and buckling. Effect of the residual stresses is favourable or detrimental which is determined by the nature and magnitude of the stress. In this research work, an attempt has been made to determine residual stress in rolled member analytically by finite element method and experimentally by hole drill method. A 3D finite element model of rolling process was developed to perform the structural analysis.Finite element analysis was performed with the aid of MSC-MARC software. Nature of residual stresses in longitudinal, transverse and along the thickness was determined. There is very good interrelationship between the values of residual stresses predicted by analytical and experimental method. The longitudinal residual stress distribution was non-uniform that causes the defects in rolled member. It can be concluded from the study that with increase in roller diameter and roller velocity residual stress was reduced.