Abstract
A numerical method for calculating lubricated contact pressures and friction in cold metal rolling is presented in this study. In order to have a good representation of the contact phenomena in lubricated metal rolling processes, the interaction between the surface roughness and lubricant flow has to be taken into account. Due to the changes in lubricant thickness during the rolling process, the lubricant flows in four local regimes: hydrodynamic thick film, hydrodynamic thin film, mixed and boundary lubrication regimes. The ability to treat all four lubrication regimes is required. Surface roughness effects, lubrication regimes treatment and lubricant property variations are all implemented within the present model. In order to calculate contact pressures and frictional forces, the Greenwood-Williamson model with the modified Reynolds lubrication equation is used. The Finite Area Method is used to discretize the Reynolds lubrication equation over a curved surface mesh. The implemented model is used as a solid contact boundary condition for a large strain hyperelastoplastic deformation solver developed in the foam-extend framework. The model is tested on wire and sheet rolling cases, and the results are presented here.
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Financial support via Ph.D. funding is gratefully acknowledged from Peter De Jaeger and Bekaert.
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Škurić, V., De Jaeger, P., Jasak, H. (2019). Lubricated Contact Model for Cold Metal Rolling Processes. In: Nóbrega, J., Jasak, H. (eds) OpenFOAM® . Springer, Cham. https://doi.org/10.1007/978-3-319-60846-4_23
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DOI: https://doi.org/10.1007/978-3-319-60846-4_23
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