Theoretical analysis based on a modified mixed-film lubrication model for metal forming processes

摘要

An analytical model for metal rolling in the mixed lubrication regime was developed based on Wilson and Chang's asperity flattening model and Von Mises homogenous deformation model. A more rigorous average Reynolds equation was used to calculate the hydrodynamic pressure. The variations of the yield stress with strain were considered in the model. An efficient iteration procedure was developed to solve the contact area, film thickness and hydrodynamic pressure. The model is more practical with fewer assumption and converges quickly. It is applicable to a wider range of rolling regimes. The calculation results using the model agree well with the literature as well as with measured data from a rolling mill.