Mechanics and modeling of cold rolling of polymeric films at large strains – A rate-independent approach

Recently a new phenomenon of bonding polymeric films in solid-state, via symmetric rolling, at ambient temperatures (≈ 20 °C) well below the glass transition temperature (Tg ≈ 78 polymer has been reported. In this type bonding, are subject to plane strain active bulk plastic compression between rollers during deformation. Here, we analyze these cold rolling processes, large strains but slow rates, by finite element modeling. We find that low temperatures, and moderate thickness reductions (at which Bauschinger effect can be neglected for particular class studied here), task material modeling is greatly simplified enables us deploy computationally efficient, yet accurate, deformation rate-independent elastic–plastic behavior (with inclusion isotropic-hardening). The based on (i) additive decomposition stretching tensor ( D = De+Dp, i.e., hypoelastic formulation) with incrementally objective time integration and, (ii) multiplicative gradient (F=FeFp) into elastic parts, programmed carried out within Abaqus Explicit. Frictional interactions modeled using consistent Coulombic law. Predictions from both formulations, decomposition, closely match experimentally observed loads. No specialized hyperelastic/visco-plastic model required describe blend under conditions described here, thereby significantly speeding up computation steady-state simulations. It revealed when principal axes show negligible rotation, formulation valid stretches. Moreover, use classical rigid-plastic (often applicable metals) found underestimate loads polymers due stretches strains. Deformation aspects solid-state sheets presented here expected facilitate development processes involving (or related to) roll-bonding polymers.