Surface texture transfer in skin-pass rolling with the effect of roll surface wear

Abstract

This paper presents a novel three-dimensional characterisation of the wear effects of a roll surface on the texture transfer in skin-pass rolling. The method integrates the interactions of the microscale elastic deformation of roll surface asperities with the microscale plastic deformation of strip surface asperities. An elasticity theory and a discrete fast Fourier transform were used to rationally predict the microscale elastic deformation of work roll in the rolling system. The microscale plastic deformation of the asperities on the soft strip surface was calculated by the material redistribution process. The Archard wear law was used to consider the wear effects with the random contact pressure, relative sliding and surface hardness. A multiscale analysis was carried out by the dynamic explicit finite element method (FEM), which fully coupled microscale surface contacts, macroscale elastic deformation of the work roll and the bulk plastic deformation of the metal strip. Due to the complexity associated with numerical simulation, a novel modularised approach was established to complete the calculation in a feasible and efficient manner. The study reveals that the roughness scale of a rolled metal strip decreases gradually due to the roll surface wear and that the rolling force, relative sliding and rolling speed at the roll-strip interface significantly affect the roll surface wear. It is expected that the method established can be used to control the surface texture transfer in skin-pass rolling under the continuous wear of roll surfaces.