Influence of work-roll grinding error and high-fidelity corrective grinding in cold sheet rolling

High-fidelity flatness defects in cold-rolled strip and sheet, arising from highly localized thickness strain variations, present an ongoing challenge to the metal industry. A primary cause of such defects, based on rolling practice, but for which effects have not been rigorously investigated, is transfer work-roll diameter deviations due roll grinding error. This study addresses high-fidelity deviation cold stainless steel, aluminum, copper. Parametric studies are performed a 4-high mill examine influences diameter, reduction, width, material work deviations. Studies conducted using efficient 3D roll-stack model that predicts profile via simplified-mixed finite element method. Reduction outgoing strip, correlate flatness/shape quantified analyzed understand characteristics relative perfectly ground (smooth) rolls. The results reveal depends only amplitudes loading, also specific locations along face length bulk deformations as well effective stiffness ratio between strip. Concluding novel approach identify customized profiles tailored specifically eliminate pre-existing defect patterns, wherein “corrective” account predicted deflections, contact force distributions, coupled micro-/macro-scale deformation mechanics.