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Multiscale Interface Stress Characterisation in Cold Rolling

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Abstract

This paper provides a comprehensive review on the multiscale characterisation of interface stresses in cold rolling considering both the random asperity deformation and lubrication. The characterisation of the microscopic interface friction was analysed with the effects of lubricant shearing, asperity sliding, lubricant additives and oil-in-water emulsion. Multiscale modelling of rolling under different lubrication regimes was discussed in detail. Some open problems for further studies were also summarised.

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Fig. 1

Adapted from Ref. [1]. Copyright (1988) with permission from Elsevier

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Adapted from Ref. [92]. Copyright (1998) with permission from Elsevier

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Abbreviations

a :

Half width of indenter

A :

Contact area ratio

A n :

Nominal contact area

α :

Pressure–viscosity coefficient

C :

Constant for pressure flow factors

C c :

Capture coefficient

d s :

Flattening of contacting asperities due to the bulk strain

δ T :

Temperature coefficient

E :

Non-dimensional strain rate

ε :

Plastic strain of bulk workpiece

\(\dot{\varepsilon }_{z}\) :

Uniform elongation strain rate along the rolling direction

ϕ c :

Volume fraction of disperse phase

ϕ d :

Volume fraction of continuous phase

ϕ x :

Average pressure flow factor along rolling direction

ϕ s :

Shear flow factor

ϕ y :

Average pressure flow factor along transverse direction

G :

Lubricant shear modulus

γ :

Surface directional pattern parameter

\(\dot{\gamma }\) :

Lubricant shear rate

h :

Nominal separation between the reference planes of two rough surfaces

H :

Dimensionless separation

H e :

Non-dimensional effective surface hardness

h T :

Average lubricant film thickness

H t :

Dimensionless average lubricant film thickness

H tc :

Percolation threshold

k :

Shear strength of workpiece

l :

Half spacing of asperities

μ :

Interface friction coefficient

μ c, μ cd , μ d and μ dc :

Viscosity coefficient for the emulsion

p :

Interface contact pressure

p a :

Asperity contact stress

p f :

Hydrodynamic pressure

r :

Constant for pressure flow factors

R :

Roll radius

σ :

Surface roughness

T :

Lubricant temperature

T 0 :

Reference temperature

τ :

Interface friction stress

τ 0 :

Eyring stress

τ a :

Asperity friction stress

τ f :

Lubricant shear stress

τ L :

Limiting shear stress

U :

Surface speed

u r :

Speed of roll surface

u s :

Speeds of strip surface

U s :

Uniform rise of the surface asperity

v a :

Downward indentation speed

v b :

Upward speed of free surface

v f :

Flattening speed of the surface asperity

W*:

Dimensionless load

x :

Coordinate measured respect to the outlet point

x 1 :

Length of the rolling bite

y :

Strip thickness

η :

Lubricant viscosity

η 0 :

Lubricant viscosity under the atmosphere pressure

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Acknowledgements

This research forms part of the Baosteel Australia Research and Development Centre (BAJC) portfolio of Projects and has received financial support from the Centre through Project BA18002. This research has also received support from the ARC Hub for Computational Particle Technology (IH140100035).

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Authors and Affiliations

  1. Laboratory for Precision and Nano Processing Technologies, School of Mechanical and Manufacturing Engineering, The University of New South Wales, Sydney, NSW, 2052, Australia

    Chuhan Wu

  2. Department of Mechanics and Aerospace Engineering, Southern University of Science and Technology, Shenzhen, 518055, China

    Liangchi Zhang

  3. Baoshan Iron & Steel Co., Ltd., Shanghai, 200941, China

    Peilei Qu, Shanqing Li & Zhenglian Jiang

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Wu, C., Zhang, L., Qu, P. et al. Multiscale Interface Stress Characterisation in Cold Rolling. Met. Mater. Int. 27, 1997–2013 (2021). https://doi.org/10.1007/s12540-020-00918-z

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