This paper identifies various modeling issues that are necessary for successful simulation of the cold rolling process by comparing it with experiments on aluminum alloys. It combines considerable experimental studies with finite element simulations using the ABAQUS/Explicit commercial finite element code to identify and evaluate modeling parameters, such as the material properties and friction laws. Damage models are incorporated in the numerical simulations by using plasticity with damage variables e.g., the Gurson-Tvergaard model with evolving porosity and Cockcroft-Latham with damage in terms of plastic work. The 3D model predictions are compared with predictions from 2D models to understand the limitations of 2D simulations in predicting the stresses, strains and evolving damage in the rolled strip.
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