Finite element modelling of surface defect evolution during hot rolling of Silicon steel

Surface defects on metal strips can be generated during hot rolling from surface cavities and indents. The size and aspect ratio of the initial surface cavities present before rolling are critical parameters that determine the final configuration of the defect. The propagation of these defect through the full rolling process is detrimental to the surface quality of the end product, in particular for electrical steel where these type of defects may directly affect the magnetic properties of the final product. A finite element model was developed in the present research to simulate the evolution of surface defects in a high-silicon electrical steel subjected to a single pass hot-rolling operation. The surface defects were modelled as predefined cavities with various aspect ratios and a multi-scale approach was used to capture the large local deformation gradients at the vicinity of the initial cavities. A user-defined subroutine was developed to describe the material constitutive behaviour at different strain rates and temperatures based on the Sellars-Tegart model in ABAQUS/standard finite element package. The modelling results were validated by laboratory scale hot rolling experiments with respect to the measured rolling forces and the plastic deformation of the initial cavities. This study shows that buckling of the lateral sides and bulging of the floor of the initial cavities are the main mechanisms involved in the formation of sub-surface defects. The developed model can be used to predict the evolution of surface cavities and to optimise the rolling parameters in order to minimise the detrimental effect of these defects in the final stages of the hot rolling process.