Damage Initiation of 15V38 Steel Bar during Square‐to‐Round Hot Rolling Process

Hot rolling processes have been extensively used to produce round bars by reducing the cross‐sectional area of continuously cast steel. The current trend toward increasing productivity often requires a more aggressive reduction per pass. Establishing safe and optimized hot rolling parameters must be determined to avoid damage while deforming the specific steel composition. Understanding the damage mechanism during the metal forming process is vital for product quality. Herein, a combined experimental and simulation approach is developed to track the evolution potential damage during hot bar rolling. Hot tension tests are conducted on as‐cast vanadium microalloyed 15V38 steel at different hot rolling temperatures and strain rate conditions to develop Johnson–Cook‐type material model. A thermomechanical finite element model is developed to simulate potential damage trends in a 12‐pass square‐to‐round and 8‐pass round‐to‐round standard industrial hot rolling process, employing damage criteria. Results are illustrated by creating a damage map at each rolling pass to determine the critical hot rolling conditions for damage initiation. Several parametric studies are also performed to illustrate the application of the suggested methodology for hot rolling process optimization. Results show that the probability of the damage initiation is higher at higher pass reductions and lower temperatures.