A new methodology to analyse iron fines during steel cold rolling processes

To optimise cold rolling process by numerical simulations, tribology, rheology and boundary conditions are needed. Thus, a methodology for accurate identification of contact conditions during cold rolling has been developed. It involves the upsetting rolling test (URT). During this specific test, the work roll slips against the strip and generates a plastic zone. The adjustment of the test is defined to simulate as well-contact pressure and effective plastic strain observed during the forming process. The mean Coulomb’s friction coefficient calculated from the URT analysis leads to a very good agreement between experimental and numerical results. Furthermore, it allows the updating of the contact conditions on numerical simulation. In addition, the developed methodology and the specific device (URT) have been used to demonstrate the mechanism of iron residues during cold rolling. We demonstrate the influence of rolling parameters in the iron residue formation. The conclusions could be directly applied on the industrial process and so improve the strip cleanliness.