Tribology in Sheet Rolling Technology

346 Pages·2016·20.02 MB·English

by  Akira Azushima (auth.)

Akira Azushima
Tribology
in Sheet
Rolling
Technology
Tribology in Sheet Rolling Technology

Akira Azushima
Tribology in Sheet Rolling
Technology
AkiraAzushima
YokohamaNationalUniversity
Yokohama,Japan
ISBN978-3-319-17225-5 ISBN978-3-319-17226-2 (eBook)
DOI10.1007/978-3-319-17226-2
LibraryofCongressControlNumber:2015946603
SpringerChamHeidelbergNewYorkDordrechtLondon
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Preface
In Japan, the steel making industries have developed rapidly in the 1960s and
1970s.Theproductionofsteelhasexceededover100milliontons,andtherolling
speedincoldsheetrollinghasexceededover2000m/min.Then,theflowstressand
thecoefficientoffrictionincoldsteelsheetrollingwithhigherrollingspeedwere
unknownparameters,sothattheparametershadintenselyinvestigatedinJapanese
steel making industries. In 1970s, the joint researches on the flow stress and the
coefficientoffrictionincoldsheetrollingwithhigherrollingspeedwerecarriedout
inISIJ.Fromthesejointresearches,thestress-straincurveinvolvingthestrainrate
andthetemperatureforhigherspeedrollingwasdeveloped,andtheexperimental
relationshipbetweencoefficientoffrictionandrollingspeedover2000m/minwas
derived. In 1980s, the friction pick up in cold sheet rolling had intensely investi-
gatedinJapanesesteelmakingindustries.Theevaluationtestingofthefrictionpick
up using tribo-simulators was carried out, so that it could be understood that an
interface temperature among the tribological parameters was most important to
evaluate the antiseizure property. Then, the microscopic analysis of the interface
phenomenabetweenrollandworkpiecehasbeencarriedoutfromtheviewpointof
thecontrolofsurfacepropertiesinISIJ.
Inhotsheetrolling,therollingoilhasbeenusedaround1970inJapan,andmany
researches on tribological behavior in hot sheet rolling were carried out in steel
making industries. In these researches, the effects of rolling oil on rolling load
reductionandrollwearreductionwereexaminedandthelubricationmechanismin
hot sheet rolling was investigated. In 1990s, researches on hot sheet rolling with
higher reduction were carried out, and in the Japanese national project on PRO-
TEUSfrom2002to2006,thehotrollingtechnologywithhigherrollingreduction
wasdevelopedinordertomanufacturetheultra-fine-grainsteel.
Ontheotherhand,from1985to1987,ajointresearchonestimationsystemof
surfacebrightnessincoldsheetrollingofstainlesssteelwascarriedoutinISIJ,and
from1989to2003,ajointresearchonmechanismoffrictionpickupincoldsheet
rollingwascarriedoutinISIJ.
v
vi Preface
Under such an environment, the author began the study of flow stress of steels
forhighspeedcoldrollinginMaster’scourseofGraduateSchooloftheUniversity
of Tokyo, and in the Doctor’s course, the experimental study of the tribological
behavior in cold steel sheet rolling with higher rolling speed and the analytical
studyoftheinletoilfilmthicknessbetweenrollandworkpiecehavebeencontin-
ued.Then,thesliding-rolling-typetribo-simulatorwasnewlydevelopedinorderto
evaluate the tribological behavior in cold sheet rolling. In Yokohama National
University, the author has studied on the tribology in cold sheet rolling and hot
sheetrollingusingthesliding-rolling-typetribo-simulatorfor30years.Theauthor
became leaders of the joint researches in ISIJ and the tribology division of the
nationalproject.
Thisbookhasbeenwrittenbasedonresearchresultspublishedbytheauthorson
thetribologyincoldsheetrollingandhotsheetrolling.Inthisbook,beforethemain
chapters,thefundamentaloftribologyandthecharacteristicsoftribologyinmetal
forming have been written. The chapters of this book are as follows: Chapter 1 is
Fundamental of Tribology, Chap. 2 is Characteristics of Tribology in Metal
forming, Chap. 3 is Fundamental of Rolling, Chap. 4 is Tribology in Cold Sheet
Rolling,andChap.5isTribologyinHotSheetRolling.
Iwouldliketoexpressmydeepthankstomanycolleaguesinjointresearches,
manycoworkerintheUniversityofTokyoandYokohamaNationalUniversity,and
Dr. Y.Tanno,Dr.S. Inagaki,Mr. K.Uda, and Mr. D. Sugawara, mycoworkerin
Yokohama National University, helped in creating figures and tables. Lastly, I
wouldliketothanktheeditorsofSpringerandmywife.
Tokyo,Japan AkiraAzushima
April2015
Contents
1 FundamentalsofTribology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Friction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 FrictioninHistory. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.2 ContactModelBetweenSurfaces
withSurfaceRoughness. . . . . . . . . . . . . . . . . . . . . . . . 2
1.1.3 JunctionGrowthofRealContactArea. . . . . . . . . . . . . 4
1.1.4 EffectofSurfaceFilm. . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.5 PlowingTerminFriction. . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.1 LubricationinHistory. . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.2 StribeckCurve. . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. 8
1.2.3 HydrodynamicLubrication. . . . . . . . . . . . . . . . . . . . . . 9
1.2.4 ElastohydrodynamicLubrication. . . . . . . . . . . . . . . . . 18
1.2.5 BoundaryLubrication. . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.6 MixedLubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3 Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3.1 AdhesiveWear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.3.2 AbrasiveWear. . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. 25
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2 TribologyinMetalforming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 CharacteristicsofTribologyinMetalforming. . . . . . . . . . . . . . . 27
2.1.1 LubricationRegime. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.1.2 ContactPressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1.3 InterfacialTemperature. . . . . . . . . . . . . . . . . . . . . . . . 30
2.1.4 SlidingSpeed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1.5 IntroducingandEntrappingLubricant. . . . . . . . . . . . . . 32
2.1.6 VirginSurface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.2 Micro-contactBetweenToolandWorkpiece. . . . . . . . . . . . . . . 34
2.2.1 HydrostaticPressure. . . . . . . . . . . . . . . . . . . . . . . . . . 34
vii
viii Contents
2.2.2 EntrappedLubricantinUpsetting. . . . . . . . . . . . . . . . . 37
2.2.3 RougheningofLubricatedSurface
byThickFilm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2.4 FreeSurfaceRoughening. . . . . . . . . . . . . . . . . . . . . . . 42
2.2.5 AsperityDeformationinUpsettingTest
andIndentationTest. . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.2.6 Micro-plastohydrodynamicLubrication
(Micro-PHL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2.7 AsperityDeformationinSheetMetalforming. . . . . . . . 52
2.2.8 OilPocketBehavioronEdgeSurfaceofCylindrical
BilletinUpsettingProcess. . . . . . . . . . . . . . . . . . . . . . 58
2.3 LubricationMechanismandFrictionalStress. . . . . . . . . . . . . . . 65
2.3.1 LubricationMechanism. . . . . . . . . . . . . . . . . . . . . . . . 65
2.3.2 FrictionalStress. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.4 LubricationMechanismandSurfaceAppearance
ofWorkpiece. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.4.1 PlastohydrodynamicLubrication. . . . . . . . . . . . . . . . . . 71
2.4.2 BoundaryLubrication. . . . . . . . . . . . . . . . . . . . . . . . . 72
2.4.3 Micro-plastohydrodynamicLubrication. . . . . . . . . . . . . 75
2.4.4 MixedLubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.5 OilFilmThicknessatInterfaceBetweenTool
andWorkpiece. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.5.1 OilFilmThicknessinSteady-State
MetalformingProcess. . . . . . . . . . . . . . . . . . . . . . . . . 76
2.5.2 OilFilmThicknessinUnsteady-State
MetalformingProcess. . . . . . . . . . . . . . . . . . . . . . . . . 80
2.6 InterfacialTemperatureBetweenToolandWorkpiece. . . . . . . . 84
2.6.1 InterfacialTemperatureRisebyFrictionEnergy. . . . . . 84
2.6.2 InterfacialTemperatureRisebyShearEnergyin
HydrodynamicLubrication. . . . . . . . . . . . . . . . . . . . . . 88
2.6.3 ComparisonofResultsCalculatedwithResults
MeasuredbyExperimentsinSheetDrawing. . . . . . . . . 88
2.7 Seizure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.7.1 SeizureinMachineElement. . . . . . . . . . . . . . . . . . . . . 90
2.7.2 SeizureinMetalforming.. . . . . . . . . . .. . . . . . . . . .. . 91
2.8 Tribo-simulationinMetalforming. . . . . . . . . . . . . . . . . . . . . . . 93
2.8.1 RelationshipBetweenTribologicalConditions
andTribologicalResults.. . . . . . . . . . .. . . . . . . . . .. . 93
2.8.2 Tribo-simulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.8.3 Tribo-simulationTestsforNewTribo-simulator
inMetalforming. . . . .. . . . . .. . . . . .. . . . . .. . . . . .. 96
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Contents ix
3 FundamentalsofRolling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.1 MechanicsofRolling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.2 RollingTheory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.2.1 Two-DimensionalHomogenousDeformation
TheoryforRolling. . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.2.2 Two-DimensionalInhomogenousDeformation
TheoryforRolling. . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.3 FlowStressforRollingTheory. . . . . . . . . . . . . . . . . . . . . . . . . 108
3.3.1 FlowStressinColdSheetRolling. . . . . . . . . . . . . . . . 108
3.3.2 FlowStressinHotSheetRolling. . . . . . . . . . . . . . . . . 111
3.4 CoefficientofFrictionforRollingTheory. . . . . . . . . . . . . . . . . 115
3.5 SimulationTestforCoefficientofFriction. . . . . . . . . . . . . . . . . 117
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4 TribologyinColdSheetRolling. . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.1 CoefficientofFriction. .. . . . . . . .. . . . . . .. . . . . . .. . . . . . .. 123
4.1.1 CoefficientofFrictioninHistory. . . . . . . . . . . . . . . . . 123
4.1.2 DependenceofCoefficientofFriction
fromRollingTheory. . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.1.3 CoefficientofFrictionMeasuredbySliding-
Rolling-TypeTribo-SimulatorDeveloped. . . . . . . . . . . 129
4.2 LubricationMechanismandRollingPressure. . . . . . . . . . . . . . . 139
4.2.1 Macro-plastohydrodynamicLubrication. . . . . . . . . . . . 140
4.2.2 BoundaryLubrication. . . . . . . . . . . . . . . . . . . . . . . . . 141
4.2.3 Micro-plastohydrodynamicLubrication. . . . . . . . . . . . . 141
4.2.4 MixedLubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.3 InletOilFilmThicknessinColdSheetRolling
withNeatOil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.3.1 CalculationofInletOilFilmThickness. . . . . . . . . . . . . 144
4.3.2 MeasurementofInletOilFilmThickness. . . . . . . . . . . 147
4.3.3 InletOilFilmThicknessforWorkpiece
withRandomSurfaceRoughness. . . . . . . . . . . . . . . . . 150
4.4 SurfaceAppearanceofWorkpieceinColdSheetRolling
withNeatOil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.4.1 SurfaceAppearancebyRollingExperiments. . . . . . . . . 157
4.4.2 SurfaceBrightnessofLowCarbonSteel. . . . . . . . . . . . 162
4.4.3 EstimationSystemforSurfaceBrightness
ofRolledSheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.5 InletOilFilmThicknessinEmulsionOil. . . . . . . . . . . . . . . . . . 177
4.5.1 EmulsionLubricationinHistory. . . . . . . . . . . . . . . . . . 177
4.5.2 EmulsionBehaviorinEHLContact. . . . . . . . . . . . . . . 181
4.5.3 InletOilFilmThicknessinColdSheetRolling
withEmulsionOil. . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.5.4 DiscussionofInletOilFilmThickness
inO/WEmulsion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.5.5 NewModelforCalculationofInletOilFilmThickness
inO/WEmulsion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191