Optimization of Ultra-Thin Strip Rolling Process Parameters on Phosphor Bronze C5191 Using Grey Relational Analysis

Ultra-thin strip rolling creates strips, used not only in microelectronics but also in UAV (unmanned aerial vehicles) battery applications. The need of the Ultra-thin strips affects the body to weight ratio in the aforementioned devices. The simulation of rolling helps to understand the in-depth changes when ultrathin strip deforms between the rollers. The tessellations generated in NEPER software considered provides the inhomogeneous material, in which deformation occurs variably after the Ultra-thin strip rolling. Among a variety of materials, phosphor bronze C5191 is considered for the present study, has wide range of microelectronic and UAV applications. Taguchi L9 orthogonal array i.e., with 3 factors viz., % reduction, coefficient of friction (COF), Roll speed are selected for the simulation analysis. The output responses i.e., roll force, von Mises stress and equivalent plastic strain (PEEQ) values obtained from ABAQUS explicit are calculated at micro level, by making an allowance for grain in-homogeneity. Ultimately it becomes a sustainable process for estimation of ultrathin strip process parameters. The 9th experiment i.e., % reduction 30, COF 0.04 and Roll speed 1.5 mm/s is the optimized result in the present study.