Understanding the generation of wear particles in cold rolling processes

In this paper, the influence of rolling parameters on the generation of wear particles is studied experimentally using a pilot scale rolling mill. Further, a multi-scale wear model is proposed to predict the amount of wear particles generated in cold rolling processes operating under the boundary lubrication. Rolling experiments revealed that thickness reduction and roll roughness are the two dominant process parameters that control wear particles generation in cold rolling processes. Analysis of the wear particles size distribution showed that most of the wear particles are less than 5 μm in diameter. The proposed model captures the trend correctly and give values in the same order of magnitude as the experiments in terms of the volume of wear particles generated.