A Two-Wavelength Model of Surface Flattening in Cold Metal Rolling with Mixed Lubrication

A new model of surface flattening is developed for cold metal rolling in the mixed regime. Longitudinal surface roughness is modeled by two separate wavelengths. The new model follows the asperity crushing analysis of Sutcliffe (1999) for unlubricated rolling but additionally includes a hydrodynamic model to account for the effect of the lubricant. The effect of various parameters including speed, reduction in strip thickness, roughness wavelength and lubricant properties is examined. The results show similar behavior to previous models of mixed lubrication, with a speed parameter A_s having the most influence, and confirm the results for unlubricated rolling that the short wavelength components of the surface roughness persist more than the long wavelength components. The predicted changes in roughness are in good agreement with experiments.