Physical modelling with application to metal working, especially to hot rolling

The simulation of metal-forming process, in particular the hot rolling of steel, using model materials and scaled deformation conditions has been reviewed. It is shown that complete similarity cannot be achieved, with significant differences evident when simulating processes where the mechanisms of deformation are important. This, and difficulties in achieving friction conditions through lubrication, limit the use of non-metallic materials such as modelling clay (Plasticine, etc.) and waxes. Commercially pure lead, generally, gives a much closer simulation and can be used under conditions of partial similarity to study the problem of metal flow and roll force. This ability is demonstrated by the simulation of the rolling of complex shapes in a laboratory mill.