In the current study, a 3D elastic-plastic FE model for rolling of large-scale aluminum ring on high-voltage switch is developed under the ABAQUS software environment. Based on the 3D FE model, lots of simulation calculations have been carried out. Through simulation, the internal energy and kinetic energy histories during the process are obtained and the optimal mass scaling factor is determined reasonably. Additionally, the stress and stain field-variables and metal flow laws have also been analyzed in detail. The ring rolling experiment was carried out and the experimental results are in good agreement with the simulation ones. The research results provide powerful guidelines for the rolling process design of large-scale aluminum ring on high-voltage switch.
