Research on Contact Behavior of Single Asperity on Work Roll Surface in Mixed Lubrication
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TECHNICAL ARTICLE—PEER-REVIEWED
Research on Contact Behavior of Single Asperity on Work Roll Surface in Mixed Lubrication Chunyu Xia . Hongbo Li . Jie Zhang
Submitted: 19 August 2017 Ó ASM International 2018
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, longterm 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. Keywords Finite element method Contact analysis Cold rolling Mixed lubrication
Introduction The study of asperity contact problem is crucial for investigating contact friction, wear and lubricating C. Xia H. Li (&) J. Zhang School of Mechanical Engineering, University of Science and Technology Beijing, Beijing 100083, China e-mail: [email protected]
properties of rough surface [1]. Chang et al. [2] calculated the maximum tangential force the single asperity can endure before yielding by using Hamilton stress field. Kimura and Childs [3] analyzed the asperity deformation behaviors with the theoretical and experimental methods, considering the persistence behavior, the influence of bulk plastic deformation and overall dimensions of the bulk flow field in a plane strain compression situation. Deshpande et al. [4] investigated indentation and sliding discrete dislocation plasticity to analyze the initiation of frictional sliding between a rigid asperity and a single crystal film. The above analyses are limited to plane stress or plane strain state. Eriten [5] proposed asperity-scale friction model essentially incorporating elastic–plastic normal loading response and preload-dependent friction coefficient models into the elastic Cattaneo–Mindlin solution. Nogueira et al. [6] supplemented some theoretical results of asperity deformation models with experimental findings based on measurements of the indention of microscopic geometry under a controlled normal load. Goda et al. [7] developed finite elements micromodels in order to determine contact, stress and strain conditions produced by a steel asperity sliding on the surface of a normally oriented fiber-rein
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