Finite element simulation of hot cladding parameters for thin-sheet rolled products made of experimental Al–2%Cu–2%Mn alloy

An analysis was performed on the temperature, rate and force parameters of the hot cladding process for the experimental Al–2%Cu–2%Mn alloy with technically pure aluminum grade 1050A, as well as on the stress-strain state of the metal in the deformation zone at reductions of 30, 40, and 50 %. Plastometric tests were conducted within the temperature range of 350–450 °C, strain rates of 0.1–20 s –1 , and true strain of 0.1–0.9, and coefficients for calculating the flow stress of the experimental alloy were determined. The thermal conductivity of the Al–2%Cu–2%Mn alloy under hot deformation conditions at temperatures of 350, 400, and 450 °C was theoretically calculated to be 161, 159, and 151 W/(m·K), respectively. The study of the cladding process on a two-high rolling mill was carried out using the QForm finite element simulation software. It was found that when the metal of the cladding layer comes into contact with the roll, its temperature decreases by approximately 100 °C, with the temperature across the height of the composite equalizing within 20–30 ms after exiting the deformation zone. The rolling force is evenly distributed between the two rolls in all cases considered, while the rolling torque on the roll on the cladding layer side is half that on the roll contacting the base layer, which is characteristic of asymmetric rolling. Points characterized by optimal bonding conditions of the rolled layers were identified, located at 10 % and 70 % of the deformation zone length along the rolling axis, where normal stresses significantly prevail over shear stresses. It was determined that the formation of these areas is due to the nature of plastic flow, including the presence of a non-deforming hard layer and a sticking zone.