Experimental validation of contact models for cold-rolling processes

Melkamu Awoke Mekicha*, M.B. de Rooij, Leonardus Joannes Matheus Jacobs, David Thomas Allan Matthews, D.J. Schipper

*Corresponding author for this work

    Research output: Contribution to journalArticleAcademicpeer-review

    Abstract

    Many functional properties of a cold rolled strip such as wear resistance, friction in a forming process, and optical properties depend on its surface finish. Accurate modelling of the real contact area is critical in predicting the surface finish of strips after cold rolling processes. The aim of this work is to experimentally verify existing contact models to predict the surface finish of industrially cold rolled strips. For this purpose, rolling trials were done on a two high mill under boundary lubricated conditions at several combinations of thickness reduction, rolling speed, and roll and strip roughness. The surface finish of the rolled strip for a given rolling condition is predicted using selected contact models. Further, a new deterministic approach to calculate the average asperity slope is proposed. Statistical properties of the three dimensional surface topography of rolled strips are compared with surfaces predicted employing selected contact models. The surface finish of measured and model-predicted surfaces showed very good agreement for strips rolled with a smooth roll. However, for strips rolled with rough rolls, a significant difference was observed in the surface height distribution between the measured and model-predicted surfaces. It was shown in these experiments that a non-uniform rise of valleys plays an important role on the surface finish of strips rolled with a rough roll.
    Original languageEnglish
    Article number116371
    JournalJournal of materials processing technology
    Volume275
    Early online date16 Aug 2019
    DOIs
    Publication statusPublished - 1 Jan 2020

    Fingerprint

    Cold rolling
    Rolling mills
    Surface topography
    Wear resistance
    Optical properties
    Surface roughness
    Friction

    Keywords

    • Cold rolling
    • Contact mechanics
    • Bulk strain
    • Strip surface topography
    • Real contact area

    Cite this

    @article{644a7e4bbff3416c901d7f6bc3c049f6,
    title = "Experimental validation of contact models for cold-rolling processes",
    abstract = "Many functional properties of a cold rolled strip such as wear resistance, friction in a forming process, and optical properties depend on its surface finish. Accurate modelling of the real contact area is critical in predicting the surface finish of strips after cold rolling processes. The aim of this work is to experimentally verify existing contact models to predict the surface finish of industrially cold rolled strips. For this purpose, rolling trials were done on a two high mill under boundary lubricated conditions at several combinations of thickness reduction, rolling speed, and roll and strip roughness. The surface finish of the rolled strip for a given rolling condition is predicted using selected contact models. Further, a new deterministic approach to calculate the average asperity slope is proposed. Statistical properties of the three dimensional surface topography of rolled strips are compared with surfaces predicted employing selected contact models. The surface finish of measured and model-predicted surfaces showed very good agreement for strips rolled with a smooth roll. However, for strips rolled with rough rolls, a significant difference was observed in the surface height distribution between the measured and model-predicted surfaces. It was shown in these experiments that a non-uniform rise of valleys plays an important role on the surface finish of strips rolled with a rough roll.",
    keywords = "Cold rolling, Contact mechanics, Bulk strain, Strip surface topography, Real contact area",
    author = "Mekicha, {Melkamu Awoke} and {de Rooij}, M.B. and Jacobs, {Leonardus Joannes Matheus} and Matthews, {David Thomas Allan} and D.J. Schipper",
    year = "2020",
    month = "1",
    day = "1",
    doi = "10.1016/j.jmatprotec.2019.116371",
    language = "English",
    volume = "275",
    journal = "Journal of materials processing technology",
    issn = "0924-0136",
    publisher = "Elsevier",

    }

    Experimental validation of contact models for cold-rolling processes. / Mekicha, Melkamu Awoke; de Rooij, M.B.; Jacobs, Leonardus Joannes Matheus; Matthews, David Thomas Allan; Schipper, D.J.

    In: Journal of materials processing technology, Vol. 275, 116371, 01.01.2020.

    Research output: Contribution to journalArticleAcademicpeer-review

    TY - JOUR

    T1 - Experimental validation of contact models for cold-rolling processes

    AU - Mekicha, Melkamu Awoke

    AU - de Rooij, M.B.

    AU - Jacobs, Leonardus Joannes Matheus

    AU - Matthews, David Thomas Allan

    AU - Schipper, D.J.

    PY - 2020/1/1

    Y1 - 2020/1/1

    N2 - Many functional properties of a cold rolled strip such as wear resistance, friction in a forming process, and optical properties depend on its surface finish. Accurate modelling of the real contact area is critical in predicting the surface finish of strips after cold rolling processes. The aim of this work is to experimentally verify existing contact models to predict the surface finish of industrially cold rolled strips. For this purpose, rolling trials were done on a two high mill under boundary lubricated conditions at several combinations of thickness reduction, rolling speed, and roll and strip roughness. The surface finish of the rolled strip for a given rolling condition is predicted using selected contact models. Further, a new deterministic approach to calculate the average asperity slope is proposed. Statistical properties of the three dimensional surface topography of rolled strips are compared with surfaces predicted employing selected contact models. The surface finish of measured and model-predicted surfaces showed very good agreement for strips rolled with a smooth roll. However, for strips rolled with rough rolls, a significant difference was observed in the surface height distribution between the measured and model-predicted surfaces. It was shown in these experiments that a non-uniform rise of valleys plays an important role on the surface finish of strips rolled with a rough roll.

    AB - Many functional properties of a cold rolled strip such as wear resistance, friction in a forming process, and optical properties depend on its surface finish. Accurate modelling of the real contact area is critical in predicting the surface finish of strips after cold rolling processes. The aim of this work is to experimentally verify existing contact models to predict the surface finish of industrially cold rolled strips. For this purpose, rolling trials were done on a two high mill under boundary lubricated conditions at several combinations of thickness reduction, rolling speed, and roll and strip roughness. The surface finish of the rolled strip for a given rolling condition is predicted using selected contact models. Further, a new deterministic approach to calculate the average asperity slope is proposed. Statistical properties of the three dimensional surface topography of rolled strips are compared with surfaces predicted employing selected contact models. The surface finish of measured and model-predicted surfaces showed very good agreement for strips rolled with a smooth roll. However, for strips rolled with rough rolls, a significant difference was observed in the surface height distribution between the measured and model-predicted surfaces. It was shown in these experiments that a non-uniform rise of valleys plays an important role on the surface finish of strips rolled with a rough roll.

    KW - Cold rolling

    KW - Contact mechanics

    KW - Bulk strain

    KW - Strip surface topography

    KW - Real contact area

    U2 - 10.1016/j.jmatprotec.2019.116371

    DO - 10.1016/j.jmatprotec.2019.116371

    M3 - Article

    VL - 275

    JO - Journal of materials processing technology

    JF - Journal of materials processing technology

    SN - 0924-0136

    M1 - 116371

    ER -