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This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming, powder metallurgy and composite material processing are briefly discussed. The range of applications of finite elements on these subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE researchers/users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for 1994‐1996, where 1,370 references are listed. This bibliography is an updating of the paper written by Brannberg and Mackerle which has been published in Engineering Computations, Vol. 11 No. 5, 1994, pp. 413‐55.

Aiming at the high temperature, high speed, high precision and high surface quality of the copper belt cold rolling, the purpose of this paper is to develop a new type of lubricant for cold rolled copper belt.

The component of the developed oil was determined based on the physical and chemical properties of the base oil and the tribological properties, the oxidation resistance properties, the rust resistance properties, the anti-foam properties, the demulsibility and the other properties of the additives. The orthogonal experiment method was used to determine the optimum adding amount of the additives; finally, the developed oil formulation was determined.

The physical and chemical experiment results show that the developed oil has a good performance of oil film bearing capacity and oxidation resistance. The simulation of rolling experiment found that the developed oil can significantly reduce rolling pressure and effectively reduce the friction in the process of rolling.

The experimental results show that the developed oil has excellent performance and can meet the requirement of lubrication in the process of cold rolling copper belt.

The purpose of this paper is to build a transient wear prediction model of surface topography of textured work roll, and then to investigate the wear performance of different original textured surfaces. The surface topography of steel sheets is one of the most important surface quality indexes, which is inherited from the textured work rolls in cold rolling. Surface topography of work roll is obviously changing in the cold rolling process. However, surface topography is difficult to measure in the industry production process.

This paper presents a numerical approach to simulate the wear process based on the mixed lubrication model of cold rolling interface developed by Wilson and Sheu (Sheu and Wilson, 1994). It is assumed that wear takes place at locations where the surfaces are in direct contact, and the volume is removed by an abrasive particle which is an abstract concept based on the wear phenomenon of textured work roll. At each simulation cycle, the distribution of the contact pressure is calculated by the lubrication model. The material is removed by an abstract abrasive particle and the surface topography is modified correspondingly. The renewed surface topography is then used for the next cycle.

Through comparative analysis, it can be found that the simulation results possess similar statistical characteristic with the measured data. A set of roughness parameters such as the amplitude, spacing and frequency-domain characteristics are introduced to analyze the wear performance of different textured surfaces. Numerical examples show that the surface topography has a significant effect on the wear performance of work roll in cold rolling.

The proposed model can accurately predict the wear process of the surface topography in the cold rolling process, which provides the foundation for optimization of original surface topography of textured work roll. The model can also be considered as a tool applicable for research on control of the surface topography of steel strip in the cold rolling process.

The purpose of this paper is to improve lubrication and anti-corrosion properties of the water-in-oil (W/O) microemulsion for rolling of copper strip and sheet to replace the traditional rolling oil.

The W/O microemulsion is prepared by using hydrogenated base oil, a deionized aqueous solution of 0.03 mol/L of Na2SO4 and composite emulsifier such as Sp20, Tx-7 or sodium petroleum sulfonate. Tribological behavior of the microemulsions and traditional cold rolling oil was conducted by MR-10A four-ball tester. The lubrication performance of microemulsion for cold rolling of copper strip was performed by cold-rolling experiment. The morphology of worn surface and the rolled copper was characterized. Anti-corrosion properties of microemulsion for rolled copper was investigated, and the corroded surface was analyzed by X-ray photoelectron spectrometer (XPS).

The results show that the extreme pressure and antiwear properties of the microemulsions have been improved; the average friction coefficient of the improved microemulsion is 0.065, which is 30% lower than the commercial cold rolling oil. For cold rolling of copper strip, the microemulsion has a higher thinning effect than the commercial cold rolling oil, and a smooth surface is obtained and the surface roughness (Sa) is decreased by 6.8%. The XPS analysis indicated microemulsion adsorbed on the copper surface mitigate the corrosion of oils.

This paper used the prepared W/O microemulsion as a new lubricant in the process of rolling for copper strip and sheet in industry, demonstrating the microemulsion has broad application prospects in the future.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-06-2020-0227/

To provide a selective bibliography for researchers working with bulk material forming (specifically the forging, rolling, extrusion and drawing processes) with sources which can help them to be up‐to‐date.

A range of published (1996‐2005) works, which aims to provide theoretical as well as practical information on the material processing namely bulk material forming. Bulk deformation processes used in practice change the shape of the workpiece by plastic deformations under forces applied by tools and dies.

Provides information about each source, indicating what can be found there. Listed references contain journal papers, conference proceedings and theses/dissertations on the subject.

It is an exhaustive list of papers (1,693 references are listed) but some papers may be omitted. The emphasis is to present papers written in English language. Sheet material forming processes are not included.

A very useful source of information for theoretical and practical researchers in computational material forming as well as in academia or for those who have recently obtained a position in this field.

There are not many bibliographies published in this field of engineering. This paper offers help to experts and individuals interested in computational analyses and simulations of material forming processes.

The purpose of this study is to improve the global optimization ability of the Tabu search (TS) algorithm, and then improve the calculation efficiency and accuracy of rolling schedule in tandem cold rolling.

A case-based reasoning–Tabu search hybrid algorithm (CBRTS) has been presented. First, the case-based reasoning technology was adopted to obtain high-quality initial solution and then the TS algorithm was used for global optimization.

The optimization effect of CBRTS is compared with that of the traditional TS algorithm, and the analysis result indicates that the CBRTS has a faster convergence rate than TS, and the optimization results are closer to the global optimal. Meanwhile, the rolling schedule calculated by CBRTS is more reasonable, which can increase the production efficiency while giving full play to the capacity of equipment.

A CBRTS hybrid algorithm is presented. The strong dependence of the TS algorithm on the initial solution has been solved. The rolling schedule multi-objective optimization functions are established. The proposed algorithm is applied in a 1,450-mm tandem cold rolling production line. The improved method can reduce about half the iterations compared with the traditional one.

In the cold rolling process, friction coefficient, oil film thickness and other factors vary dramatically with the change in the rolling speed, which seriously affects the strip thickness deviation. This paper aims to improve the strip control precision with the forecast roll gap model based on CF-PSO-SVM approach in the rolling process.

In this paper, a novel forecasting model of the roll gap based on support vector machine (SVM) optimized by particle swarm optimization with compression factor (CF-PSO) is proposed. Based on lots of online data, the roll gap models regressed by PSO-SVM, genetic algorithm (GA)-SVM and CF-PSO-SVM are obtained and verified through evaluating the performances with the decision coefficient (R²), mean absolute error and root mean square error. In addition, with the good forecasting performances of CF-PSO-SVM, a roll gap compensation model is studied.

The results indicate that the proposed CF-PSO-SVM has excellent learning regression ability compared with other optimization algorithms. Meanwhile, a roll gap compensation model based on the rolling speed and plastic coefficient is obtained, which has been proved validated in product.

In this paper, the SVM algorithm is combined with traditional rolling technology to solve the problems in actual production, which has great supporting significance for the improvement of production efficiency.

Studying manufacturing process of compressor blade can reduce the production cost and time in aircraft turbo‐engine industries. In the cold roll‐forging of thin compressor blades, the elastic behavior of machine structure and rolls is considerable due to the higher volume of roll separating force. Owing to this kind of elastic deformation during rolling, the adjusted gap between the rolling dies is increased and this causes unexpected flow of material, shape and thickness. The purpose of this paper is to present a new approach for simulation of cold rolling of thin blades and studying the effect of elastic behavior of the machine structure as well as rolls deflection on the material flow and roll separating force.

In this paper, the process has been investigated using experimental test and simulation by introducing a new approach in a decision‐making flowchart. Instead of simulating of the entire system structure, a couple of virtual deformable rolls are suggested. The specifications of these rolls are selected to behave elastically during rolling same as whole roll stand. In addition, the thickness values are compared in both experiment and simulation. Also, the roll separating force is compared with and without using this approach.

A decision‐making algorithm has been presented that can be used to study the process. This finding provides the basis to investigate the effect of elastic deformation of machine structure and rolls on dimensional accuracy and roll force.

Result of this work can promote the position of simulation of the thin rolled sections to an extent more compatible with reality. For instance, the amount of increased gap between two dies during rolling can be estimated accurately. Also the influence of this gap on final blade thickness and the roll force and on the roll torque can be investigated by this approach.

In the process of cold rolled strip, there is tight coupling between flatness control and gauge control. The variation of the roll gap caused by the change of bending force will lead to the change of rolling force. Furthermore, it can cause a deep impact on the control accuracy of strip exit thickness and exit crown. The purpose of this paper is to improve the accuracy of the bending force preset value for cold rolled strip.

In this paper, the bending force preset control strategy with considering of rolling force was proposed for the first time and the preset objective function of bending force was established on the basis of the two-objective optimization of bending force and rolling force. Meanwhile, the multi-objective intelligent algorithm – INSGA-II – was used to solve the objective function.

The proposed bending force multi-objective preset model has been tested in a 1,450 mm tandem cold rolling line. The analyzed results of field data show that the deviations of strip exit thickness and exit crown are reduced effectively by using the improved model, and at the same time, more reasonable bending force preset values are obtained, which can enhance the accuracy of flatness preset control.

A preset model of bending force with considering flatness and gauge is proposed in this paper and the multi-objective function of bending force preset is established on the basis of the two-objective optimization of bending force and rolling force. The value lies in proposing a new decoupling method of rolling force and bending force.

The last stage of the cold rolling process is skin-pass rolling and one of its most significant goals is to obtain appropriate topography on the surface of the sheet steel used extensively such as in automotive industry. The purpose of this paper is to investigate the effect of thickness change and various reduction ratios on roughness transfer of DC04 grade sheet material.

DC04 grade sheet materials with different reduction ratios and several thicknesses were subjected to skin-pass rolling process in the rolling equipment with a two-high roll. Some roughness parameters were determined as a result of roughness measurements from the surfaces of roughened sheet materials.

While the roughness transfer is higher in 1-mm thick material in reduction ratios up to 430 micrometers; in reduction ratios above 430 micrometers, it is higher for 1.5-mm thick materials. As the reduction ratio increases in DC04 grade sheet materials, the homogeneity of the roughness distribution in 1-mm thickness sheet material deteriorates, while the roughness distribution in 1.5-mm thickness sheet material is more homogeneous.

This paper demonstrates how material thickness and reduction ratio affect the roughness transfer in skin-pass rolling. The results obtained can be used by optimizing in manufacturing processes.