Abstract
This research makes a two-dimensional model for a cold flat rolling process using the ANSYS program. The contact pair is used between the contact surfaces using the boundary condition of the surface-to-surface contact. The process of symmetric rolling is tested for two types of materials (aluminum and mild steel). The rolling force for (1%) to (25%) reduction of a slab of dimensions of (200 * 10) mm using (Avitzur) theoretical equations and ANSYS. The radius of the rolls for aluminum is (75) mm and that for mild steel is (300) mm. The numerical results were compared with (Avitzur) theoretical equations. The comparison shows that the values of forces calculated using (Avitzur) theoretical equations are accurate enough up to (5%) reduction, and the numerical results proved its accuracy up to (25%) reduction. The study shows that forces increase as a result of increasing the rolling metal area at the entry rate. The angle of the neutral point was also studied in this work and it is found that it decreases with the increasing reduction rate, due to an increase in the cohesion area on the sliding one within the rolling process while the theoretical results failed to calculate the angle of the neutral point correctly.