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Example of finite element simulation of rolling process

Description of the simulation

Rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness or changing the cross section of a long work piece by compressive force applied through a set of rolls.

In our case, the three dimensional FEA model of rolling was established in CAD CATIA V5R20 which included two rollers and a billet. Diameter of the rollers is 300 mm and the dimensions of the rectangular billet are length 500 mm thickness 50 mm. The CAD model was saved in the STP format and imported to ANSYS academic version 19.2. Static structural analysis was performed under which equivalent stress, directional deformation and equivalent strain was calculated. Materials used for the two rollers are structural steel and billet is aluminium. Maximum stress is equal to 637.71MPa.

FEA simulation of rolling process


Directional deformation

Equivalent elastic strain

Equivalent stress

Total deformation


Prateek Prakash Srivastava