Bending behavior and control mechanism of Ti/Al composite plates under an unconventional Asymmetric rolling configuration

Ti/Al composite plates exhibit significant potential for industrial applications by combining the complementary characteristics of both metals. However, the inherent asymmetry between the constituent metals leads to post-rolling bending, which restricts their practical application. Therefore, a systematic investigation of deformation behavior during composite rolling and how rolling parameters affect bending characteristics is essential. In this study, an unconventional asymmetric rolling configuration is proposed, where the high-speed roll contacts the Al layer instead of the conventional Ti side. The rolling process was simulated using ABAQUS, and the results were validated through experiments. The evolution of stress-strain distributions in both layers was systematically analyzed. Results show that alternating plastic deformation occurs between Ti and Al within the deformation zone. At the roll exit, unsynchronized cessation of plastic deformation and greater elastic recovery of the Al layer cause bending toward the Ti side. Under the proposed configuration, the high-pressure regions are redistributed to generate a reverse bending moment that counteracts the bending moment induced by the cross-shear zone, thereby stabilizing the process. This also modifies strain rate band characteristics and interlayer deformation coordination. Increasing the speed ratio causes the composite to bend from the Ti side to near-flatness, then to the Al side, and finally back to the Ti side. Increasing the reduction ratio decreases sensitivity to the speed ratio, while a higher thickness ratio improves deformation coordination and suppresses bending. This study provides an effective rolling method for manipulating the shape of dissimilar metal composite plates.