Professional Documents
Culture Documents
Lubetests Coldrolling Smeulders 0215
Lubetests Coldrolling Smeulders 0215
Lubetests Coldrolling Smeulders 0215
Iron & Steel Technology © 2015 Association for Iron & Steel Technology
Table 1 Figure 3
Typical Mill Conditions of a 5-Stand Tandem Mill (Stand 5 Omitted)
Stand 1 Stand 2 Stand 3 Stand 4
Reduction (%) 30 40 30 30
Contact length (mm) 17 16 12 11
Oil volume (mm3) 16.2 15.8 11.8 10.6
Contact time (ms) 2.4 1.5 0.7 0.5
Flux of oil (ml/second) 6.8 10.6 16.2 23.2
stands 1–4, and assume further a strip width of 1.6 m, to the oscillatory nature of many tests, and to the
strip entry gauge of 3 mm, strip exit speed of 1,700 resulting periodic stresses on, especially, the softer
m/minute, an average oil film thickness of 0.3 mm, of the mating surfaces, fatigue wear can occur, which
and assuming only oil enters the contact. Further, is unlikely to happen on the strip surface during the
both strip sides are accounted for in Table 1. passage in the five stands in the mill. An example
On the basis of these estimates, it can be calcu- is shown in Figure 3. Furthermore, in some long-
lated how much oil passes through the bites and how duration tests, adhesion processes can occur. This
long the oil is subjected to strong frictional condi- involves the transfer (or welding) of the softer mate-
tions. This amounts to 60 ml/second, 200 l/hour or rial onto the harder tool. This roughens the surface
5 m3 per day. This can be compared with the total significantly, and will influence the rest of the test,
amount of oil present in the system, which is also 5 i.e., it is an undesirable history effect. An example
m3. This means that on average, every oil particle is of a cylinder, having been loaded and oscillated on
exposed to in-bite conditions roughly once per day. a soft steel panel, and which is damaged by adhesion
Assuming an average residence time of 1 ms, and a is shown in Figure 4.
refreshment rate of the oil of once per 15 days, the
total exposure of the oil to the frictional conditions
in the bite is on the order of 0.015 second. This is of
course vastly different from the exposure of the oil Emulsions Instead of Neat Oils
to high temperatures in some laboratory tests. This
calculation shows that long-term, high-temperature Some of the more traditional lubrication tests for
lubrication tests for cold rolling lubricants are not cold rolling lubricants use neat oil as the test
recommended. fluid, even though emulsions are used in the field.
We can also look at the wear processes that some- Furthermore, lubrication provided by emulsions may
times occur in (long-duration) laboratory tests. Due differ from that of neat oils, on three accounts:
Figure 4 Figure 5
Tribometer tool with adhesion. Schematic illustration of the lower film formation of emulsions compared to neat
oils.
Iron & Steel Technology © 2015 Association for Iron & Steel Technology
Figure 8
lubrication (BL) regime, representative
of adsorption processes on the mating
surfaces. The coefficient of friction in
this regime may depend on the emul-
sion composition. As speeds increase,
the separation between the mating sur-
faces generally increases, and we enter
the mixed lubrication (ML) regime.
Depending on the film formation prop-
erties of the emulsion, the transition
from BL to ML may occur at differ-
ent speeds for different emulsions. At
the highest speeds, further differences
between emulsions may be found. This
Film thickness measurement. may have two reasons. First, it can
be due to film formation. With an
emulsion that supplies sufficiently thick
Figure 9 films to the contact, the EHL regime
may be approached, whereas with an
emulsion that supplies thinner films
to the contact, ML conditions will be
maintained. Second, it may be due to
the value of the CoF in the EHL regime,
mainly influenced by the lubricant’s
viscosity at high pressures, as explained
earlier.2,9 In Figure 9, clear differences
between the emulsions can be seen.
On a pilot mill (not gauge controlled,
i.e., constant roll force), the achieved
reductions at a rolling speed of 300 m/
minute were 25%, 31% and 34% for
emulsions S1, S2 and S3, respectively.
Stribeck curve.
FP 0.5 m FN Dv vs (m/second) 5 11 28
FPI = = FN (specific) (ton/m) 900 1,150 1,100
A A
µ (–) 0.08 0.04 0.035
(Eq. 1) FPI (W/mm2) 17 45 100
EP (mJ/mm2) 38 37 19
where
DTf (°C) 60 90 110
µ = the CoF,
The factor 0.5 is due to the fact that the power is (Eq. 3)
divided over two surfaces. In frictional processes, we
can also define the energy pulse10 (EP), which is where
the total amount of frictional energy a tribo-surface
receives per unit area; i.e., it is the FPI multiplied by µ = the average coefficient of friction in the contact,
the time of duration tc , as shown in Equation 2. Its
units are J/m2. FN = the load,
Iron & Steel Technology © 2015 Association for Iron & Steel Technology
The value of b (thermal contact coefficient) is a is governed by the CoF in the boundary and EHL
function of thermal diffusivity k, density ρ and spe- regimes, as well as the film formation processes
cific heat Cp (for steel k = 55 W/mK, ρ = 7,800 kg/ immediately in front of the contact. As was discussed
m3, Cp = 460 J/kgK, b = √(k ρ Cp) = 1.41·104). The earlier, these properties depend significantly on the
equation by Blok is equally valid in a tribometer as lubricant (and emulsion) composition, and thus the
it is in cold rolling, so the required conditions in the test result is representative of the emulsion’s rheo-
tribometer can be calculated to mimic the flash tem- logical and tribological properties. Furthermore, the
peratures in cold rolling. occurrence of a failure is a sign that the particular
As shown above, the FPI and EP, and DTf of any surface chemistry that prevents metallic contact (i.e.,
stand/pass in the cold rolling process can be esti- scuffing) is insufficient. This chemistry is of course
mated, and these values mimicked in the tribometer. the result of the reaction of the lubricant’s ep/aw
The rolling conditions considered in this report are additives with the steel surfaces in aqueous environ-
those for stands 2 and 4 in a tandem sheet rolling ment. Any shortcomings in this respect are shown
mill, and stand 5 in a tinplate mill. See Table 2 for by a failure. Of course, a failure in the test does not
some characteristic values. The tribometer consists imply a radically deficient performance in the field.
of a ball loaded onto a disc. In order to achieve It indicates only a shortcoming in lubrication (on the
the required frictional conditions and flash tem- microscopic scale) under the chosen conditions.
peratures, the ball and disc speeds as well as the load
were carefully chosen. For the first set of tests, the
FPI and EP were satisfied simultaneously. In these
tests, also the contact times, relevant in view of in- Examples
contact reaction times of ep/aw additives, are similar
to those in cold rolling. Furthermore, the “recupera- In Figures 11–14, some examples are given of the
tion times,” relevant in view of the time available for correlation of the newly developed emulsion tests
the ball surface to equilibrate again in its rolling mimicking frictional power intensity and flash tem-
emulsion environment before it enters the contact peratures with the performance in the field. The
again, is similar to that for the work roll in cold roll- values of the CoF, as well as the tendency for a failure
ing. For the second set of tests, the flash temperature in the test, may correlate with field performance.
was satisfied. In both sets of tests, sheet rolling stands Figure 11 shows the results for two different emul-
2 and 4 and tinplate rolling stand 5 were mimicked. sions, with a low and high ester content. The emul-
So there were six tests in total. sion with the higher ester content passes all tests
In Figure 10, a typical result is given of the six tests, with relatively low CoF values, while the other fails
referred to as FP2, FP4, FP5 and Tf2, Tf4, Tf5 for in three tests. It is commonly known that ester-based
the tests mimicking frictional power intensity and products perform much better in the field, with
flash temperatures, respectively. It can be seen that lower roll forces and higher speeds attainable.
the coefficient of friction decreases, which is due to Figure 12 gives the test results of an emulsion at
a mild wear process, leading to some decrease in various concentrations. It is well known that rolling
roughness. It can also be concluded from the typical performance improves with emulsion concentration,
CoF values obtained in these tests, ranging between with the largest effect for the lower concentration
0.06 and 0.09, that lubrication occurs in the mixed range. This is clearly reflected in the test results,
lubrication regime. Test results are generally given as where increased emulsion concentration leads to
the average CoF during the last quarter of the test, as lower CoF values, but especially less tendency for fail-
shown by the columns in Figure 10b. A further strik- ures. The effect is most noticeable between 0.5 and
ing phenomenon in these (severe!) tests is that some- 1.5%. At higher concentrations, no further improve-
times a failure occurs, accompanied by scuffing and ment in test results is seen.
high friction, after which the test is stopped. In such In Figure 13 are plotted the results of emulsions of
cases, the CoF is not shown in the “column” plot. three model products and one commercial product,
Note that the Tf5 test is the most severe. Crucially, in which were also tested on a pilot mill mentioned in
these tests, significant differences are found between the text discussing Figure 9. It can be seen that the
various emulsions, depending on the composition CoF values decrease going from Emulsion M1 via M2
of the product, but also on the emulsion concentra- and M3 to C1, accompanied by a decreased tendency
tion. Differences are found both in terms of the CoF for a failure. On the pilot mill, the achieved reduc-
values in the six tests as in the occurrence of failures. tions at a rolling speed of 300 m/minute increased
The tests are interpreted as follows. The CoF val- from 26%, via 31% and 35% to 42%, respectively.
ues, as mentioned, are representative of the mixed Figure 14 plots the results of a reference emulsion
lubrication regime. This means that the friction that was run by a customer, but which was replaced
Results of the roll bite mimicking tests showing the influence of ester Conclusion
content.
In this paper, novel lubrication tests on
emulsions are discussed. These not only
involve film formation measurements
Figure 12 and Stribeck curves, but also explore
the boundary lubrication under severe
conditions, where the influence of ep/
aw additives is seen. Carrying out these
measurements on emulsions takes into
account the various influences the
presence of water has on fundamental
physico-chemical processes in the entry
zone and the roll bite. Due to the use of
emulsions, severe in-contact conditions
cannot be recreated by greatly increas-
ing the temperature, but instead are
obtained by mimicking the frictional
power intensity and flash temperatures
Results of the roll bite mimicking tests showing the influence of emul- typically encountered in cold rolling.
sion concentration.
The Stribeck curves and also these roll
bite mimicking tests show a good cor-
relation with field experience.
Figure 13
Results of the roll bite mimicking tests for four different emulsion com-
positions, which correlate well with pilot mill performance.
Iron & Steel Technology © 2015 Association for Iron & Steel Technology
Figure 14
References
1. Reynolds, O., “On the Theory of Lubrication
and Its Application,” Phil. Trans. R. Soc.,
Vol. 177, pp. 157–234 (1886).
2. Smeulders, J.B.A.F., “Lubrication in the
Cold Rolling Process Described by a 3D
Stribeck Curve,” Iron & Steel Technology,
Vol. 10, No. 2, 2014, pp. 37–45.
3. Kimura, Y., and Okada, K., “Film Thickness
at Elastohydrodynamic Conjunctions
Lubricated With Oil in Water Emulsions,”
Proc. ImechE, Vol. 176, 1987, pp. 85–90.
4. Bergmann, M.; Zeman, K.; Kainz,
A.; Krimpelstätter, K.; Paesold, D.;
Schellingerhout, P.; and Smeulders, B.,
“Mixed Lubrication Model for Cold Rolling
Considering the Inlet and Deformation
Zones,” Proceedings of the ASME 2012 Improved results of the roll bite mimicking tests of a modification,
International Manufacturing Science and which also performed better in a production mill.
Engineering Conference MSEC2012, 4–8
June 2012, Notre Dame, Ind., USA.
5. Wilson, W.R.D.; Sakaguchi, Y.; and Schmid,
S.R., “A Dynamic Concentration Model for
Lubrication With Oil in Water Emulsions,”
Wear, Vol. 161, 1993, pp. 207–212.
6. Barus, C., “Isothermals, Isopiestics and Isometrics Relative
to Viscosity,” Am. J. of Science, Vol. 45, 1983, pp. 87–96. Bas Smuelders is a research scientist in The Netherlands for
Quaker Chemical Corp.
7. Roelands, C.J.A., “Correlation Aspects of the Viscosity-
901 East Hector St.
Temperature Relationship of Lubricating Oils,” Ph.D. thesis,
Conshohocken, PA 19428 USA
Delft, 1966.
+1.800.523.7010
8. Ree, F.H.; Ree, T.; and Eyring, H., “Relaxation Theory of www.quakerchem.com
Transport Problems in Condensed Systems,” Ind. Eng.
Chem., Vol. 50, 1958, pp. 1036–1040.
9. Smeulders, J.B.A.F., “Roll Cooling and Lubrication in Cold
Rolling, in The Making, Shaping and Treating of Steel®, Flat
Products Volume, AIST, 2014, Chapter 13.2.
10. Plint, M.A., and Alliston-Greiner, A.F., “The Energy Pulse: A
New Wear Criterion and Its Relevance to Wear in Gear Teeth
and Automotive Engine Valve Trains,” Lub. Sci., Vol. 8, No.
3, April 1996, pp. 233–251.
11. Blok, H., “The Flash Temperature Concept,” Wear, Vol. 6,
1963, pp. 483–494. F