Journal of Failure Analysis and Prevention

, Volume 15, Issue 2, pp 320–326 | Cite as

Contact Deformation Analysis of Elastic–Plastic Asperity on Rough Roll Surface in a Strip Steel Mill

Technical Article---Peer-Reviewed

Abstract

In this paper, the deformation behaviors of elastic–plastic asperity on rough roll surface in a strip steel mill were simulated by a three-dimensional finite element (FE) model. The asperity characterized a sinusoidal profile and all objects in the FE model were elastic–plastic with linear strain hardening. The deformation behaviors including contact stresses, strains (including elastic and plastic strains), and contact radii of different rolling force densities and different geometrical shapes and sizes were calculated and analyzed. It revealed that the tall-thin type asperity caused larger plastic strain in the asperity itself and larger Von Mises stress in the mating roll subsurface. Long-term repeated effects of large cyclic strain and stress were liable to spark subsurface cracks and increased the risk of fatigue failure of rolls in strip rolling mills.

Keywords

FE method Contact analysis Elastic–plastic deformation Strip rolling mill 

Notes

Acknowledgment

The authors would like to acknowledge the financial support provided by the Specialized Research Fund for the Doctoral Program of Higher Education of China (Grant No. 20120006110015).

References

  1. 1.
    H. Hertz, On the contact of elastic solids. J. Reine. Angew. Math. 92, 156–171 (1882)Google Scholar
  2. 2.
    M.R. Brake, An analytical elastic-perfectly plastic contact model. Int. J. Solids Struct. 49(22), 3129–3141 (2012)CrossRefGoogle Scholar
  3. 3.
    K.L. Johnson, Contact Mechanics (Cambridge University Press, Cambridge, 1985)CrossRefGoogle Scholar
  4. 4.
    M.J. Bryant, H.P. Evans, R.W. Snidle, Plastic deformation in rough surface line contacts—a finite element study. Tribol. Int. 46(1), 269–278 (2012)CrossRefGoogle Scholar
  5. 5.
    J.A. Greenwood, J.B.P. Williamson, Contact of Nominally Flat Surfaces. Proc. R. Soc. A 295(1442), 300–319 (1966)CrossRefGoogle Scholar
  6. 6.
    C.C. Lo, Elastic contact of rough cylinders. Int. J. Mech. Sci. 11(1), 105–106 (1969)CrossRefGoogle Scholar
  7. 7.
    J.A. Greenwood, J.H. Tripp, The contact of two nominally flat rough surfaces. Proc. Inst. Mech. Eng. 185, 625–634 (1970)CrossRefGoogle Scholar
  8. 8.
    W.R. Chang, An elastic–plastic model for the contact of rough surfaces. J. Tribol. 109(2), 257–263 (1987)CrossRefGoogle Scholar
  9. 9.
    S. Kucharski, T. Klimczak, A. Polijaniuk, J. Kaczmarek, Finite-elements model for the contact of rough surfaces. Wear 177(1), 1–13 (1994)CrossRefGoogle Scholar
  10. 10.
    U. Sellgren, S. Björklund, S. Andersson, A finite element-based model of normal contact between rough surfaces. Wear 254(11), 1180–1188 (2003)CrossRefGoogle Scholar
  11. 11.
    M. Liu, Finite element analysis of large contact deformation of an elastic–plastic sinusoidal asperity and a rigid flat. Int. J. Solids Struct. 51(21–22), 3642–3652 (2014)CrossRefGoogle Scholar
  12. 12.
    N.K. Arakere, G. Subhash, Work hardening response of M50-NiL case hardened bearing steel during shakedown in rolling contact fatigue. Mater. Sci. Technol. 28(1), 34–38 (2012)CrossRefGoogle Scholar
  13. 13.
    V. Moorthy, B.A. Shaw, An observation on the initiation of micro-pitting damage in as-ground and coated gears during contact fatigue. Wear 297(1–2), 878–884 (2013)CrossRefGoogle Scholar
  14. 14.
    H.C. Eden, J.E. Garnham, C.L. Davis, Influential microstructural changes on rolling contact fatigue crack initiation in pearlitic rail steels. Mater. Sci. Technol. 21(6), 623–629 (2005)CrossRefGoogle Scholar
  15. 15.
    Q. Dong, J.-G. Cao, H.-B. Li, Y.-S. Zhou, T.-L. Yan, W.-Z. Wang, Analysis of spalling in roughing mill backup rolls of wide and thin strip hot rolling process. Steel Res. Int. 86(2), 129–136 (2015)CrossRefGoogle Scholar
  16. 16.
    M.S. Prasad, S.K. Dhua, C.D. Singh, A. Ray, Genesis of spalling in tandem mill work-rolls: some observations in microstructural degeneration. J. Fail. Anal. Prev. 5(6), 30–38 (2005)CrossRefGoogle Scholar
  17. 17.
    R. Colás, J. Ramıŕez, I. Sandoval, J.C. Morales, L.A. Leduc, Damage in hot rolling work rolls. Wear 230(1), 56–60 (1999)CrossRefGoogle Scholar
  18. 18.
    R.D. Mercado-Solis, J. Talamantes-Silva, J.H. Beynon, M.A.L. Hernandez-Rodriguez, Modelling surface thermal damage to hot mill rolls. Wear 263(7–12), 1560–1567 (2007)CrossRefGoogle Scholar
  19. 19.
    J.A. Greenwood, J.H. Tripp, The elastic contact of rough spheres. J. Appl. Mech. 34(1), 153–159 (1967)CrossRefGoogle Scholar
  20. 20.
    Y.F. Gao, A.F. Bower, K.S. Kim, L. Lev, Y.T. Cheng, The behavior of an elastic–perfectly plastic sinusoidal surface under contact loading. Wear 261(2), 145–154 (2006)CrossRefGoogle Scholar
  21. 21.
    F. Bucher, K. Knothe, A. Theiler, Normal and tangential contact problem of surfaces with measured roughness. Wear 253(1–2), 204–218 (2002)CrossRefGoogle Scholar
  22. 22.
    A.A. Bandeira, P. Wriggers, Pimenta P. de Mattos, Numerical derivation of contact mechanics interface laws using a finite element approach for large 3D deformation. Int. J. Numer. Method Eng. 59(2), 173–195 (2004)CrossRefGoogle Scholar

Copyright information

© ASM International 2015

Authors and Affiliations

  1. 1.School of Mechanical EngineeringUniversity of Science and Technology BeijingBeijingChina

Personalised recommendations