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The purpose of this paper is to explore the deformation mechanism of void generation around inclusions inside the sheet during sheet rolling processes. The plastic deformation and flow pattern of the sheet with inclusions inside during sheet rolling were simulated by the rigid-plastic finite element method. The inclusions are assumed to be rectangular or round and located at the center of the sheet. The effects of various rolling conditions, such as the dimension of the inclusion, the distances between two inclusions, etc., on the generation and development of voids anticipated to occur in the front and rear of the inclusion and mean stress distributions at the roll gap during rolling were discussed. The critical thickness reductions under which void generation can be avoided were also investigated. Furthermore, experiments on sheet rolling with an inclusion inside the sheet were conducted. The theoretical predictions of the dimensions of the voids after rolling were compared with experimental results and relatively good agreement between them was found.

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