Tribology in Sheet Rolling Technology, 1st ed. 2016

This book provides an in-depth description of the fundamental tribological aspects of cold and hot sheet rollings. The author describes new developments in the rolling processes, the rolling oils, the rolling rolls and the structural materials resulting from sheet rolling technology and their practical applications. The author includes comprehensive details on both friction and lubrication in rolling.

1. Fundamental of Tribology
1.1  Friction
1.1.1 Friction in history
1.1.2 Contact model between surfaces with surface roughness
1.1.3 Junction growth and real contact area
1.1.4 Effect of surface film
1.1.5 Plowing term in friction
1.2  Lubrication
1.2.1 Lubrication in history
1.2.2 Stribeck curve
1.2.3 Hydrodynamic lubrication
1.2.3.1   Reynolds equation
1.2.3.2   Plane bearing
1.2.3.3   Journal bearing
1.2.3.4   Rolling bearing
1.2.3.5   Pressure distribution of journal and rolling bearings
1.2.3.6   Elasto-hydrodynamic lubrication (EHL)
1.2.3.7   Effect of viscosity of lubricant
1.2.3.8   Elastic deformation
1.2.4 Boundary lubrication
1.2.4.1   Boundary lubrication model
1.2.4.2   Boundary film
1.2.5 Mixed lubrication
1.3  Wear
1.3.1 Adhesive wear
1.3.2 Abrasive wear
References

2. Tribology in metalforming
2.1  Characteristics of tribology in metalforming
2.1.1 Lubrication regime
2.1.2 Contact pressure
2.1.3 Interfacial temperature
2.1.4 Sliding speed
2.1.5 Introducing and entrapping lubricant
2.1.6 Virgin surface
2.2  Micro-contact between tool and workpiece
2.2.1   Hydrostatic pressure
2.2.2   Entrappe

d lubricant in upsetting 
2.2.3   Roughening of lubricated surface by thick film
2.2.4   Free surface roughening
2.2.5   Asperity deformation in upsetting test and indentation test
2.2.5.1   Dry condition
2.2.5.2   Lubricated condition
2.2.6   Micro-plasto-hydrodynamic lubrication (Micro-PHL)
2.2.7   Asperity deformation in sheet metal forming
2.2.8   Oil pocket behavior on edge surface of cylinder billet in upsetting process
2.3  Lubrication mechanism and frictional stress
2.3.1 Lubrication mechanism
2.3.2 Friction stress2.3.2.1   Plasto-hydrodynamic lubrication
2.3.2.2   Boundary lubrication
2.3.2.3   Micro-hydrodynamic lubrication
2.3.2.4   Mixed lubrication
2.4  Lubrication mechanism and surface appearance of workpiece
2.4.1 Plasto-hydrodynamic lubrication
2.4.2 Boundary lubrication
2.4.3 Micro-plasto-hydrodynamic lubrication
2.4.4 Mixed lubrication
2.5  Oil film thickness at interface between and workpiece
2.5.1 Oil film thickness in steady state metalforming process
2.5.1.1   Constant viscosity
2.5.1.2   Viscosity depending on pressure
2.5.1.3   Viscosity depending on pressure and temperature
2.5.2 Oil film thickness in unsteady state metalforming process
2.5.2.1   Upsetting at high compression speed
2.5.2.2   Upsetting at low compression speed
2.6  Interfacial temperature between tool and workpiece
2.6.1 Interfacial temperature rise by friction energy
2.6.2 Interfacial temperature rise by shear energy in hydrodynamic lubrication
2.6.3 Comparison of results calculated with results measured by experiments in sheet drawing
2.7  Seizure
2.7.1 Seizure in machine element
2.7.2 Seizure in metalforming
2.8  Tribo-simulation in metalforming
2.8.1 Relationship between tribological conditions and tribological results
2.8.2 Tribo-simulator
References

3. Fundamental of Rolling
3.1  Mechanics of rolling
3.2  Rolling theory
3.2.1 Two dimensional homogenous theory for rolling
3.2.2 Two dimensional in-homogenous theory for rolling
3.3  Flow stress for rolling theory
3.3.1 Flow stress in cold sheet rolling
3.3.2 Flow stress in hot sheet rolling
3.4  Coefficient of friction for rolling theory
3.5  Simulation test for coefficient of friction
References

4. Tribology in Cold Sheet Rolling
4.1 Coefficient of fricition4.1.1 Coefficient of friction in history
4.1.2 Dependence of coefficient of friction from rolling theory
4.1.2.1   Coefficient of friction in neat oils
4.1.2.2   Coefficient of friction in emulsion oil

4.1.3 Coefficient of friction measured by sliding-rolling type tribo-simulator
4.1.3.1   Evaluation of coefficient of friction measure
4.1.3.2   Evaluation of additive in mineral base oil by coefficient of friction
4.1.3.3   Evaluation of tallow base oil by coefficient of friction
4.1.3.4   Evaluation of mixed rolling oil of mineral base oil tallow oil by coefficient of      friction
4.2  Lubrication mechanism and rolling pressure
4.2.1 Macro-plasto-hydrodynamic lubrication
4.2.2 Boundary lubrication
4.2.3 Micro-plasto-hydrodynamic lubrication
4.2.4 Mixed lubrication
4.2.4.1   Combination of hydrodynamic lubrication and boundary lubrication
4.2.4.2   Combination of hydrostatic lubrication and boundary lubrication
4.2.4.3   Combination of hydrodynamic lubrication, hydrostatic lubrication and boundary lubrication
4.3  Inlet oil film thickness in cold sheet rolling with neat oil
4.3.1 Calculation of inlet oil film thickness
4.3.2 Measurement of inlet oil film thickness
4.3.3 Inlet oil film thickness for workpiece with random surface roughness
4.4  Surface appearance in cold sheet rolling with neat oil
4.4.1 Surface appearance by rolling experiment
4.4.1.1   Effect of rolling speed and reduction on surface appearance
4.4.1.2   Effect of viscosity of lubricant on surface appearance
4.4.1.3   Effect of surface roughnesses of roll and sheet
4.4.2 Surface brightness of low carbon steel
4.4.2.1   Surface brightness for roll and sheet with smooth surface
4.4.2.2   Effect of roll surface on surface brightness
4.4.2.3   Effect of surface roughness of sheet on surface brightness4.4.2.4   Relationship between surface brightness and inlet oil film thickness
4.4.3 Estimation system for surface brightness of rolled sheet
4.4.3.1   Outline of new estimation system
4.4.3.2   Evaluation of estimation system in joint research
4.4.3.3   Simulation method
4.4.3.4   Simulation results
4.4.3.5   Improvement of surface brightness
4.5  Inlet oil film thickness in emulsion oil
4.5.1 Emulsion lubrication in history
4.5.2 Emulsion behavior in EHL contact
4.5.3 Inlet oil film thickness in cold sheet rolling with emulsion oil
4.5.3.1   Analysis of inlet oil film thickness by dynamic concentration model
4.5.3.2   Calculated results of inlet oil film thickness
4.5.3.3   Comparison of inlet oil film thickness calculated with that measured
4.5.4 Discussion of inlet oil film thickness in O/W emulsion
4.5.5 New model for calculation of inlet oil film thickness in O/W emulsion
4.6  Surface appearance of workpiece in emulsion oil
4.6.1 Comparison of surface appearance in O/W emulsion oil with that in neat oil
4.6.2 Effect of tribological conditions on surface appearance with emulsion oil
4.6.2.1   Effect of emulsion property on surface brightness
4.6.2.2   Effect of oil property on surface quality
4.6.3 Surface brightness irregularity of stainless steel with O/W emulsion
4.7  Interfacial temperature in cold sheet rolling
4.7.1 Calculation of interfacial temperature in cold sheet rolling
4.7.2 Temperature measurement of roll surface by thermocouple
4.7.3 Temperature measurement of interface between roll and sheet by thermoelectric method
4.8  Friction pick up (Heat streak)
4.8.1 Friction pick up in history
4.8.2 Simulation for friction pick up
4.8.2.1   Evaluation of anti-seizure property of tallow oil
4.8.2.2   Evaluation of anti-seizure property of commercial oils4.8.3 Development of commercial oil with high anti-seizure property
4.8.4 Estimation of anti-seizure property in cold sheet tandem mill of stainless steel
4.8.4.1   Evaluation of anti-seizure property by slip rolling type tribo-simulator
4.8.4.2   Evaluation of anti-seizure property by normal rolling
4.8.4.3   Estimation of mean interfacial temperature in tandem mill
4.9  Cold rolling oil
4.9.1 Cold rolling oil in history
4.9.1.1   Emulsion particle
4.9.1.2   Plating out
4.9.2 Development of new rolling oil with high lubricity
4.9.2.1   Experimental
4.9.2.2   Results
4.10 Cold roll
4.10.1 Cold roll in history
4.10.2 Evaluation of anti-seizure property of commercial rolls
4.10.2.1   Experimental
4.10.2.2   Results
4.10.3 Development of roll with high anti-seizure property
4.10.3.1   Experimental
4.10.3.2   Results
4.10.4 Verification of relationship between limitation reduction and carbide mean spacing
4.10.5 Application of new developed roll to cold tandem mill
4.10.6 Evaluation of surface treated rolls
References

5. Tribology in hot sheet rolling
5.1  Tribology in hot sheet rolling in history
5.1.1 Actual hot tandem mill
5.1.2 Laboratory mill
5.1.2.1   Effect of lubricant on rolling load
5.1.2.2   Effect of tribological factor
5.2  Coefficient of friction
5.2.1 Coefficient of friction in history
5.2.2 Coefficient of friction measured by SRV testing machine
5.2.3 Coefficient of friction measured by hot sliding-rolling type tribo-simulator developed newly
5.2.3.1   Hot sliding-rolling type tribo-simulator
5.2.3.2   Effect of surface roughness of roll on coefficient of friction
5.3  Lubrication mechanism

5.4  Friction model
5.4.1 Emulsion concentration of c ＞ 1.0%
5.4.2 Emulsion concentration of c ＜ 1.0%5.4.3 Effect of surface roughness of roll on coefficient of friction
5.4.4 Effect of roll speed on coefficient of friction
5.4.5 Confirmation of friction law
5.5  Friction pick up
5.5.1 Friction pick up in history
5.5.2 Friction pick up of carbon steel with high strength
5.6  Scale on workpiece surface
5.6.1 Characteristics of scales
5.6.2 Effect of scale thickness on coefficient of friction
5.6.3 Effect of scale composition on coefficient of friction
5.6.4 Effect of Si content on coefficient of friction
5.7 Scale on roll surface
5.7.1 Scale on roll surface in history
5.7.2 Formation condition of black scale layer
5.7.2.1   Effect of sale thickness of sheet surface on formation condition
5.7.2.2   Effect of composition of sheet on formation condition
5.7.2.3   Effect of emulsion concentration on formation condition
5.7.2.4   Effect of base oil and additive on formation condition
5.8  Hot rolling lubricant
5.8.1 Hot rolling lubricant in history
5.8.2 Evaluation of hot rolling oil by hot sliding-rolling type tribo-simulator
5.8.3 Development of hot rolling oil for stainless steel
5.8.4 Development of rolling oil with hot rolling with large reduction
5.8.4.1   Previous consideration
5.8.4.2   Experiments and results
5.9 Hot roll
5.9.1 Hot roll in history
5.9.2 Development of hot roll for hot rolling with high reduction
5.9.2.1   Previous consideration
5.9.2.2   Results
References

Dr. Akira Azushima is a Professor Emeritus at Yokohama National University in Japan.