Mathematical modeling of multipass hot deformation of aluminum alloy AA5083-model development and validation

Hot rolling, a critical step in the manufacturing of sheet products, influences the final sheet properties based on the microstructure evolution during this operation. A comprehensive mathematical model of the hot rolling process for aluminum alloys has been developed. This article outlines the development of a two-dimensional (2-D) mathematical model to simulate multipass hot rolling using the commercial finite element (FE) package, ABAQUS. Microstructure evolution during multipass rolling was modeled using a physically based approach to predict the stored energy and the resulting microstructure for an AA5083 aluminum alloy. The stored energy in the material between passes is quantified using a rule-of-mixtures approach based on the fraction of the material that is recrystallized. An extensive experimental program was undertaken to validate the model using Corus' single-stand reversible rolling facility located in IJmuiden, The Netherlands. Overall, the model was able to simulate the thermomechanical history experienced during multipass hot rolling reasonably well based on comparison to temperature and rolling load measurements. The model was also able to predict the fraction recrystallized through the thickness of the strip reasonably well, but the grain size predictions were consistently low.