A simple and accurate approach to modeling deformation processes that are highly constrained by boundary conditions is presented. The method involves a detailed finite element analysis of the most controlling aspects of the process. Additional analysis of the material states of texture and anisotropy are calculated as deemed necessary. The method is applied to the rolling process with a detailed analysis of the rolling of aluminum sheet. Particular attention is paid to the analysis of the roll gap geometry and the transfer of tractions from the roll to the workpiece. The calculated deformation state is then applied to a more detailed calculation of material texture which tracks the motion of individual crystalites due to macroscopic boundary conditions. Results are compared to experimentally determined through thickness texture gradients in rolled aluminum alloys, and the use of the method as a process design tool is discussed.
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