Surface texture transfer in skin-pass rolling under mixed lubrication

This paper presents a novel integrated approach to modeling surface texture transfer in skin-pass rolling under mixed elasto-plasto-hydrodynamic lubrication (EPHL). The innovation lies in combining discrete fast Fourier transform (DC-FFT) for precise characterisation of elastically deformed asperities on the roll surface, dynamic explicit finite element analysis (FEA) for capturing cross-scale deformations, and a transient average Reynolds equation for governing the lubrication flow. By integrating these methods, the model addresses the complex interplay between elastic roll deformation, microscale asperity-lubricant interactions, and elastoplastic strip deformation, providing a more comprehensive understanding of texture transfer mechanisms. In addition, the model predictions are validated by experimental results. Furthermore, this study investigates the effects of rolling speed and surface pattern orientation, revealing that higher speeds reduce texture transfer while surface patterns aligned with the rolling direction enhance it. These insights demonstrate the potential of this integrated modeling approach for advancing the field of skin-pass rolling.