A numerical strategy for predicting the interface stresses in metal strip rolling with small reduction

This paper has developed a numerical strategy for predicting the interface stresses in metal strip rolling at a small reduction. Key rolling factors such as the roll elasticity, fluid lubrication, random asperity contacts, asperity-lubricant interaction, rolling speed and reduction were comprehensively integrated into the numerical analysis. The random asperity contact at the roll-strip interface was addressed by a statistical approach with considering the elastoplastic deformations of surface asperities. A transient average Reynolds equation was utilised to deal with the fluid flow subjected to the interruptions caused by the asperity contacts. With the aid of a dynamic explicit finite element analysis, a novel modularised strategy was established to systematically accommodate the mathematical models governing the above key rolling factors, which allows the affordable computation and the effective predictions of contact characteristics in the strip rolling. It was found that both the lubrication and microscale asperity contacts disturb considerably the contact stresses at the rolling interface, and that a proper selection of rolling conditions can reasonably regulate the stresses.