Skip to main content
SpringerLink
Log in

Research on Contact Behavior of Single Asperity on Work Roll Surface in Mixed Lubrication

  • Technical Article---Peer-Reviewed
  • Published:
Journal of Failure Analysis and Prevention Aims and scope Submit manuscript

Abstract

The present paper focuses on asperity contact during cold rolling at a microscopic level. As analyses of such a contact are not practical with experimental facilities, a three-dimensional finite element method (FEM) is adopted to simulate the indentation and furrow behaviors of a single asperity on work roll surface in mixed lubrication. The effects of the tensile stress, the hydrodynamic pressure and the plastic deformation of steel strip are considered comprehensively. Most calculations are done for parabolic asperities, but for comparison purposes, some results are presented for sinusoidal and elliptical asperities. The indentation behaviors including uplift height of edges and plastic deformations of strip steel are calculated and analyzed. The friction during furrow behaviors is also considered. It reveals that the reduction and lubrication condition has a significant effect on the uplift height of strip steel edges around the asperity. Furthermore, long-term repeated effects of mixed lubrication contact are liable to spark asperity wear and decrease the roughness of rolls and even cause the failure of rolls in strip rolling mills.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16

Similar content being viewed by others

References

  1. K.L. Johnson, Contact Mechanics (Cambridge University Press, Cambridge, 1985)

    Book  Google Scholar 

  2. W.R. Chang, I. Etsion, D.B. Bogy, Static friction coefficient model for metallic rough surfaces. ASME J. Tribol. 110(1), 57–63 (1988)

    Article  Google Scholar 

  3. Y. Kimura, T.H.C. Childs, Surface asperity deformation under bulk plastic straining conditions. Int. J. Mech. Sci. 41(3), 283–307 (1999)

    Article  Google Scholar 

  4. V.S. Deshpande, D.S. Balint, A. Needleman, E. Van der Giessen, Size effects in single asperity frictional contacts. Model Simul. Mater. Sci. Eng. 15(1), S97–S108 (2007)

    Article  Google Scholar 

  5. M. Eriten, Multiscale Physics-Based Modeling of Friction (University of Illinois Urbana-Champaign, Urbana, 2012)

    Google Scholar 

  6. I. Nogueira, F. Robbe-Valloire, R. Gras, Experimental validations of elastic to plastic asperity-based models using normal indentations of rough surfaces. Wear 269(11), 709–718 (2010)

    Article  Google Scholar 

  7. T. Goda, K. Váradi, K. Friedrich, H. Giertzsch, Finite element analysis of a polymer composite subjected to a sliding steel asperity part I normal fibre orientation. J. Mater. Sci. 37(8), 1575–1583 (2002)

    Article  Google Scholar 

  8. R.L. Jackson, L. Kogut, A comparison of flattening and indentation approaches for contact mechanics modeling of single asperity contacts. J. Tribol. 128(1), 209–212 (2006)

    Article  Google Scholar 

  9. T.D.S. Botelho, R. Progri, G. Inglebert, F. Robbe-Valloire, Analytical and experimental elastoplastic spherical indentations of a layered half-space. Mech. Mater. 40(10), 771–779 (2008)

    Article  Google Scholar 

  10. Z. Song, K. Komvopoulos, Elastic–plastic spherical indentation: deformation regimes, evolution of plasticity, and hardening effect. Mech. Mater. 61(8), 91–100 (2013)

    Article  Google Scholar 

  11. M. Liu, H. Proudhon, Finite element analysis of frictionless contact between a sinusoidal asperity and a rigid plane: elastic and initially plastic deformations. Mech. Mater. 77, 125–141 (2014)

    Article  Google Scholar 

  12. Q. Dong, J. Cao, Contact deformation analysis of elastic-plastic asperity on rough roll surface in a strip steel mill. J. Fail. Anal. Prev. 15(2), 320–326 (2013)

    Article  Google Scholar 

  13. S.W. Lo, T.C. Yang, H.S. Lin, The lubricity of oil-in-water emulsion in cold strip rolling process under mixed lubrication. J. Tribol. 66, 125–133 (2013)

    Article  Google Scholar 

  14. W.R.D. Wilson, S. Kalpakjian, Low-speed mixed lubrication of metal-forming processes. Ann. CIRP 44(1), 205–208 (1995)

    Article  Google Scholar 

  15. T.D. Ta, A.K. Tieu, H. Zhu, Q. Zhu, P.B. Kosasih, J. Zhang, G. Deng, Tribological behavior of aqueous copolymer lubricant in mixed lubrication regime. ACS Appl. Mater. Interfaces 8(8), 5641–5652 (2016)

    Article  Google Scholar 

  16. D. Xu, J. Zhang, H. Li, J. Lu, Q. Fan, H. Dong, Research on surface topography wear of textured work roll in cold rolling. Ind. Lubr. Tribol. 67(3), 269–275 (2015)

    Article  Google Scholar 

  17. A.S. Galakhar, J.D. Gates, W.J.T. Daniel, P.A. Meehan, Adhesive tool wear in the cold roll forming process. Wear 271(11), 2728–2745 (2011)

    Article  Google Scholar 

  18. S. Huart, M. Dubar, R. Deltombe, A. Dubois, L. Dubaret, Asperity deformation, lubricant trapping and iron fines formation mechanism in cold rolling processes. Wear 257(5), 471–480 (2004)

    Article  Google Scholar 

  19. R. Li, Q. Zhang, X. Zhang, M. Yu, B. Wang, Control method for steel strip roughness in two-stand temper mill rolling. Chin. J. Mech. Eng. 28(3), 573–579 (2015)

    Article  Google Scholar 

  20. B. Lorentz, A. Albers, A numerical model for mixed lubrication taking into account surface topography, tangential adhesion effects and plastic deformations. Tribol. Int. 59, 259–266 (2013)

    Article  Google Scholar 

Download references

Acknowledgments

The authors would like to express their appreciation for the continuous supports from National Natural Science Foundation of China (No. 51404023), the National Key Technology R&D Program of the 12th Five-year Plan of China (No. 2015BAF30B01), National Natural Science Foundation of China (No. 51604024), Project Funded by China Postdoctoral Science Foundation (No. 2016M590042) and Fundamental Research Funds for the Central Universities (No. FRF-TP-15-001A1).

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, University of Science and Technology Beijing, Beijing, 100083, China

    Chunyu Xia, Hongbo Li & Jie Zhang

Authors
  1. Chunyu Xia
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Hongbo Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jie Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Hongbo Li.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Xia, C., Li, H. & Zhang, J. Research on Contact Behavior of Single Asperity on Work Roll Surface in Mixed Lubrication. J Fail. Anal. and Preven. 18, 75–82 (2018). https://doi.org/10.1007/s11668-017-0382-4

Download citation

  • Received:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11668-017-0382-4

Keywords

Search

Navigation