Experimental evaluation and FE simulation of the asymmetrical rolling process of bimetal rods

Purpose Roll-formed products that are custom-made provide flexible and effective answers for various aerospace uses. The purpose of this study is experimental tests and finite element (FE) simulation of the asymmetrical rolling process of bimetal rods. Design/methodology/approach Bimetal rods are fabricated using horizontal core-filling casting equipment (the inner layer is of aluminum [Al] and the outer layer is of copper [Cu]). Al and Cu materials undergo tension testing to obtain true stress–true strain curves. An asymmetric rolling machine is used to experimentally roll the bimetal rods. In addition, ABAQUS software is used to conduct FE simulation of the bimetal rod rolling process. Findings A comparison is conducted between the experimental and numerical results to examine the geometric parameters of the bimetal rod after asymmetric rolling. In addition, an investigation is carried out into the impact of various reductions on the geometric dimensions of the rod’s cross-section, the curvature radius and the contact force between the rolls and the bimetal rod within a range of rotational velocities of the rollers. One of the most important results shows the decrease in the rod’s radius of curvature after rolling shows a correlation with the increase in the reduction of rod cross-section. Originality/value The bimetallic rod is fabricated using a horizontal core-filling casting device and subsequently tested via an asymmetric rolling test on an asymmetric rolling machine.