Investigation of Material Flow During Linear Flow Splitting Using Tracer Diffusion Experiments and Finite‐Element Simulations

The deformation behavior and evolution of strain distributions of flat metal sheets subjected to the high‐strain forming process of linear flow splitting (LFS) are studied using experimental and numerical techniques. The new tracer gradient method for the mapping of material flow based on diffusional concentration gradients is proposed. The method is validated using theoretical predictions for rolling of a sheet and shown to overcome the limitations of previous techniques. A parametric finite‐element model for LFS of a HC800LA grade steel is developed and validated against the results of the tracer gradient method. A sensitivity study is undertaken to investigate the effects of strain‐hardening behavior and sheet thicknesses on the LFS process. A good agreement between experimental and numerical results is obtained, with the friction between rolls and sheet found to be a critical parameter in the modeling of the process. It is further observed that the formation of the characteristic steady state in the LFS process is linked to the material‐hardening behavior and not the geometry of the sheet.