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We analyze plane strain cold rolling processes, at large strains but slowstrain rates, by finite element modeling. At low temperatures, slow strainrates, and moderate thickness reductions during rolling (at which Bauschingereffect can be neglected for the particular class of polymeric films studiedhere), the task of material modeling is greatly simplified, and enables us todeploy a computationally efficient, yet accurate, finite deformationrate-independent elastic-plastic material behavior (with inclusion ofisotropic-hardening). The finite deformation elastic-plastic material behaviorbased on (i) hypoelasticity, and ii) multiplicative plasticity, are programmedand carried out for cold rolling within Abaqus Explicit. Predictions from boththe formulations, i.e., hypoelastic and multiplicative decomposition, exhibit aclose match with the experimentally observed rolling loads. We find that nospecialized hyperlastic/visco-plastic material model is required to describethe behavior of the particular blend of polymeric films, under the conditionsdescribed here, thereby significantly speeding up the computation forsteady-state rolling simulations. Moreover, the use of classical rigid-plasticmodeling (which is often applicable to metals) is found to greatlyunderestimate the rolling loads for polymers, due to large elastic stretches inthe polymer films at large strains.

Mechanics and Modeling of Cold Rolling of Polymeric Films at Large Strains -- A Rate-Independent Approach