Walzkraftberechnung für das Kaliberwalzen

Research output: ThesisMaster's Thesis

Organisational units


In addition to the prediction of the rolling force and rolling moment demand, the expected final geometry of the deformed workpiece, and the microstructural distribution during the forming process are the main objectives of metal forming. In order to support the mill workers in the selection and implementation of force and geometry calculation, this work deals with the process of caliber rolling. It examines the formation of the rolling force and the final geometry of the rolling stock by means of analytical calculation methods and FEM simulation. For this purpose, the passes of type square-diamond, diamond-square and square-oval were calculated. The analytical calculation includes four approaches for the calculation of the relevant sizes for each pass. The average height was determined on the one hand, with the method of the maximum width, and on the other iteratively. For the calculation of the contact area the empirical formulas derived by Zouhar and the calculation with the average width were used. FEM simulations were applied analogously to the analytical calculations and carried out with the DEFORM3D™ program. The comparison of the results suggests that the iterative method for determining the average height is meaningful only in the case of a redesign of a caliber and the method of maximum width is sufficient for the calculation of existing calibers. By using the average width for calculating the contact area, the biggest mistake is made because the contact area is not similar to a square in most of the calibers. The simulation provides in addition to the rolling force the distribution of strain and strain rate, which can be determined in the analytical calculation only as averages. This allows identifying areas with high strain or strain rates and these findings can be included in considerations of microstructural formation in the rolling stock. Nevertheless, the results of the simulation have to be considered critically, as each simulation is a simplified representation of reality. In addition to rolling trials, mill workers should use a combination of analytical calculations and critically considered FEM simulation to achieve an economic production.


Translated title of the contributionRolling force calculation for caliber-rolling
Original languageGerman
Award date24 Oct 2014
Publication statusPublished - 2014