A multi-scale model for friction in cold rolling of aluminium alloy

H. R. Le, M. P. F. Sutcliffe

    Research output: Contribution to journalArticle

    6 Citations (Scopus)

    Abstract

    A simple and robust friction model is proposed for cold metal rolling in the mixed lubrication regime, based on physical phenomena across two length scales. At the primary roughness scale, the evolution of asperity contact area is associated with the asperity flattening process and hydrodynamic entrainment between the roll and strip surfaces. The friction coefficient on the asperity contacts is related to a theoretical oil film thickness and secondary-scale roll surface roughness. The boundary friction coefficient at the “true” asperity contacts is associated with tribo-chemical reactions between fresh metal, metal oxide, boundary additives, the tool and any transfer layer on the tool. The asperity friction model is verified by strip drawing simulations under thin film lubrication conditions with a polished tool, taking the fitting parameter of the boundary lubrication friction factor on the true contact areas equal to 0.1. Predicted values of average friction coefficient, using a boundary friction factor in the range 0.07–0.1, are in good agreement with measurements from laboratory and industrial rolling mill trials.
    Original languageEnglish
    Pages (from-to)95-104
    Number of pages10
    JournalTribology Letters
    Volume22
    Issue number1
    DOIs
    Publication statusPublished - Apr 2006

    Fingerprint

    multiscale models
    cold rolling
    Cold rolling
    aluminum alloys
    coefficient of friction
    Aluminum alloys
    friction factor
    friction
    Friction
    lubrication
    strip
    boundary lubrication
    Lubrication
    entrainment
    flattening
    Metals
    metals
    metal oxides
    chemical reactions
    surface roughness

    Keywords

    • Metal rolling
    • Friction
    • Multi-scale modelling
    • Lubrication

    Cite this

    Le, H. R. ; Sutcliffe, M. P. F. / A multi-scale model for friction in cold rolling of aluminium alloy. In: Tribology Letters. 2006 ; Vol. 22, No. 1. pp. 95-104.
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    A multi-scale model for friction in cold rolling of aluminium alloy. / Le, H. R.; Sutcliffe, M. P. F.

    In: Tribology Letters, Vol. 22, No. 1, 04.2006, p. 95-104.

    Research output: Contribution to journalArticle

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    AU - Sutcliffe, M. P. F.

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    AB - A simple and robust friction model is proposed for cold metal rolling in the mixed lubrication regime, based on physical phenomena across two length scales. At the primary roughness scale, the evolution of asperity contact area is associated with the asperity flattening process and hydrodynamic entrainment between the roll and strip surfaces. The friction coefficient on the asperity contacts is related to a theoretical oil film thickness and secondary-scale roll surface roughness. The boundary friction coefficient at the “true” asperity contacts is associated with tribo-chemical reactions between fresh metal, metal oxide, boundary additives, the tool and any transfer layer on the tool. The asperity friction model is verified by strip drawing simulations under thin film lubrication conditions with a polished tool, taking the fitting parameter of the boundary lubrication friction factor on the true contact areas equal to 0.1. Predicted values of average friction coefficient, using a boundary friction factor in the range 0.07–0.1, are in good agreement with measurements from laboratory and industrial rolling mill trials.

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