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TECHNICAL PAPERS

A Friction Model for Cold Strip Rolling With Two-Wavelength Surface Roughness in the “Mixed” Lubrication Regime

[+] Author and Article Information
H. R. Le, M. P. F. Sutcliffe

Cambridge University Engineering Department, Trumpington Street, Cambridge, CB2 1PZ, UK

J. Tribol 125(3), 670-677 (Jun 19, 2003) (8 pages) doi:10.1115/1.1538191 History: Received December 11, 2001; Revised September 24, 2002; Online June 19, 2003
Copyright © 2003 by ASME
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References

Sutcliffe,  M. P. F., and Johnson,  K. L., 1990, “Lubrication in Cold Strip Rolling in the ‘Mixed’ Regime,” Proc. Inst. Mech. Eng., Part B: J. Eng. Manufacture, 204, pp. 249–261.
Sheu,  S., and Wilson,  W. R. D., 1994, “Mixed Lubrication of Strip Rolling,” STLE Tribol. Trans., 37, pp. 483–493.
Lin,  H. S., Marsault,  N., and Wilson,  W. R. D., 1998, “A Mixed Lubrication Model for Cold Strip Rolling-Part I: Theoretical,” STLE Tribol. Trans., 41(3), pp. 317–326.
Marsault, N., Montmitonnet, P., Deneuville, P., and Gratacos, P., 1998, “A Model of Mixed Lubrication for Cold Rolling of Strip,” Proc. NUMIFORM 98, Twente University, Netherlands, A. A. Balkema (Rotterdam), pp. 715–720.
Sutcliffe,  M. P. F., 1988, “Surface Asperity Deformation in Metal Forming Processes,” Int. J. Mech. Sci., 30, pp. 847–868.
Wilson,  W. R. D., and Sheu,  S., 1988, “Real Area of Contact and Boundary Friction in Metal Forming,” Int. J. Mech. Sci., 30, pp. 475–489.
Christensen,  H., 1970, “Stochastic Models for Hydrodynamic Lubrication of Rough Surfaces,” Proc. Inst. Mech. Eng., 104, Pt 1, pp. 1013–1022.
Patir,  N., and Cheng,  H. S., 1978, “An Average Flow Model for Determining Effects of Three-Dimensional Roughness on Partial Hydrodynamic Lubrication,” ASME J. Lubr. Technol., 100, pp. 12–17.
Patir,  N., and Cheng,  H. S., 1979, “Application of Average Flow Model to Lubrication Between Rough Sliding Surfaces,” ASME J. Lubr. Technol., 101, pp. 220–230.
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Sutcliffe,  M. P. F., and Le,  H. R., 2000, “Measurements of Surface Roughness in Cold Metal Rolling in the Mixed Lubrication Regime,” STLE Tribol. Trans., 43(1), pp. 39–44.
Le,  H. R., and Sutcliffe,  M. P. F., 2000, “Analysis of Surface Roughness of Cold-Rolled Aluminum Foil,” Wear, 244, pp. 71–78.
Le,  H. R., and Sutcliffe,  M. P. F., 2000, “A Two-Wavelength Model of Surface Flattening in Cold Metal Rolling With Mixed Lubrication,” STLE Tribol. Trans., 43(4), pp. 595–602.
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Figures

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Schematic of the strip rolling process
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Cross-section of the contact between a smooth roll and strip with a two-wavelength surface roughness. The rolling direction is out of the plane of the figure: (a) when roll and strip first contact, and (b) after some asperity flattening.
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Plan view of the geometry of the contact patch between a smooth roll and rough strip with a two-wavelength surface roughness
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A flow chart of the numerical procedure
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Evolution of hydrodynamic pressure in valleys across the width as for conditions of 10, r=25 percent,ur=0.1 m/s
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Evolution of the depth of valleys across the width as for conditions of 10, r=25 percent,ur=0.1 m/s
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Comparison of predicted and measured surface roughness as for conditions of 13, r=25 percent
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Comparison of predicted and measured surface roughness as for conditions of 13, r=50 percent
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Comparison of predicted and measured average friction coefficients in rolling as for conditions of 10, μa=0.09
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Surface flattening rate predicted by Korzekwa et al. 24. The curves are fitted to the data using a least square method

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