Aluminum/steel rolled composite finite element secondary development simulation and experimental study

Given the significant difference in the properties of the two metals, the rolled composite has a severe problem of uncoordinated deformation and low bond strength. The effect of the same diameter and different diameters of the rolls and single roll drive on the composite plate’s coordinated deformation and bond strength is investigated. Simulation modeling employs finite element (FE) secondary development, and the plate warpage mechanism is analyzed by combining synchronous and asynchronous rolling experiments. The aluminum side is subjected to compressive stresses in the rolling direction during the rolling process. The steel side is subjected to tensile stresses in the rolling direction. The roll diameter in contact with the aluminum plate is reduced, the rolling pressure is distributed more evenly along the vertical plate section direction, improving deformation coordination. The side of the roll that touches the aluminum is driven, and the bimetal starts to bond closer to the exit of the roll. The frictional stresses and bending moments between the bimetallic interface are smaller, resulting in better deformation coordination and higher bond strength.