Journal of Materials Processing Technology 213 (2013) 17641771

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Journal of Materials Processing Technology

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Inuence of roll radius on contact condition and material deformation in

skin-pass rolling of steel strip
Hideo Kijima
Rolling and Processing Research Department, JFE Steel Corporation, 1, Kokan-cho, Fukuyama, Hiroshima, Japan

a r t i c l e

i n f o

Article history:
Received 1 October 2012
Received in revised form 25 April 2013
Accepted 27 April 2013
Available online 6 May 2013
Keywords:
Skin-pass rolling
Temper rolling
Finite element analysis

a b s t r a c t
Skin-pass rolling (or temper rolling) is the nal forming step in the production of cold rolled steel sheets.
Although a large roll radius compared to the contact length is one of the characteristics of skin-pass
rolling conditions, numerous studies have been conducted thus far using laboratory mills with small
radius rolls. In this paper, the inuence of roll radius on the contact condition and material deformation
in skin-pass rolling is examined and claried by numerical analysis by an elasticplastic FEM analysis
as well as experimental rolling tests, which were performed to verify the result of the analysis. Some
characteristics of skin-pass rolling related to pressure distribution, contact condition and material deformation are not properly simulated using small radius rolls. Considering characteristic skin-pass rolling
conditions, two cases using simplied models, i.e., vertical compression and rolling with a circular, rigid
roll, were analyzed.
2013 Elsevier B.V. All rights reserved.

1. Introduction
Skin-pass rolling (or temper rolling), usually following the
annealing process, is the nal operational step in the production
of cold rolled steel sheets, and has a great inuence on mechanical properties including Lderband prevention, surface topography,
strip atness and so on. The parameter settings in skin-pass rolling
are quite different from those in conventional plate rolling due to
the small reduction (app. 1%), large contact length compared to the
sheet thickness, large roll radius compared to the contact length
and high friction. Considering those conditions, it is expected that
material deformation will not be uniform in the through-thickness
direction, and the inuence of the elastic deformation of the rolls
on material deformation will be crucial.
Most of the early literatures on theoretical/numerical modeling
of skin-pass rolling simplied either the inhomogeneous material
deformation or the elastic deformation of the rolls. In the former
approach, the slab method combining precise, non-circular elastic
analysis of work roll deformation (Jortner et al., 1960) was used to
calculate the rolling force for certain conditions. Fleck et al. (1992)
developed a realistic model to describe an aluminum foil rolling
process which includes a long at region where the strip thickness
does not change. Their model had been used to develop models
of skin-pass rolling. Krimpelsttter et al. (2004) utilized a regularized Coulomb friction law to express a sliding region and a sticking

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E-mail address: h-kijima@jfe-steel.co.jp
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http://dx.doi.org/10.1016/j.jmatprotec.2013.04.011

region (a no-slip-zone). The thickness distribution inside the roll

gap is similar to the results from FE simulation mentioned later,
qualitatively. Domanti et al. (1994) analyzed a wet skin-pass rolling
condition, in which the friction coefcient was modeled as around
0.05, with the foil rolling model. They showed the same thickness distribution pattern in wet skin-pass rolling as in foil rolling.
Matsumoto and Shiraishi (2008) separately calculated a skin-pass
rolling condition with the long at region, and proposed a model to
stabilize the convergence calculation which allows elastic deformation of the strip in the at region. All those studies focused on and
succeeded in practical rolling force calculations, respectively, by
considering the non-circular deformation of the work roll, whereas
the mechanism of the material deformation was not claried.
In the latter approach, the rolls were modeled as circular and
rigid with a attened radius, and inhomogeneous, elasticplastic
deformations of the material were analyzed by FE model. Yarita
and Itoh (2008) compared the calculated rolling load with the slab
method and concluded that the both results showed good agreement under a small friction and small roll condition. Kijima and
Bay (2006, 2007) showed that the skin-pass rolling process can be
modeled as plane strain upsetting of a sheet strip with long narrow
tools and claried the basic mechanism of inhomogeneous material
deformation and the contact condition for the case of high friction
and smooth tool surfaces.
Although a large roll radius compared to the contact length is
one of the characteristics of skin-pass rolling, numerous studies
have been conducted thus far using laboratory mills with small
radius rolls, mainly in order to investigate roughness transfer from
the rolls to the material. Kimura et al. (2009) showed that the large

H. Kijima / Journal of Materials Processing Technology 213 (2013) 17641771

1765

Large roll
Roll center
Work roll

R/2

Rotation

Small roll
Rigid

R250
x 150

Deformed

R50 x 100

0.69t x 50w x 300L

h0/2

Elastic
Workpiece
Elastic-plastic

z
x

0.69t x 80w x 300L

Fig. 1. Laboratory rolling mills.

roll could enlarge the roughness transfer for the same elongation.
Nevertheless, the inuence of roll radius on roughness transfer
has not been discussed in relation to the mechanism of material
deformation in the literature.
Recently, some papers have shown that skin-pass rolling conditions can be successfully analyzed by commercial FE analysis
programs, even combining elasticplastic deformation of the material and elastic deformation of the roll. Sun et al. (2009) numerically
showed the effects of elongation, friction coefcient, yield stress
and entry/delivery tension on the pressure and shear stress distributions and elastic roll deformation patterns. As a result, they
concluded that any factor that increases the rolling load may lead
to elongation of the central at region, but they did not discuss
the mechanism of material deformation. Akashi et al. (2008) investigated the jumping phenomenon in wet skin-pass rolling with a
bright work roll (Imai et al., 1980) and proposed a mechanism for
its occurrence in relation to the friction coefcient.
In the present paper, the inuence of roll radius on the contact
condition and material deformation is investigated numerically and
experimentally in rolling of relatively soft, medium-to-heavy gauge
steel strip with relatively smooth rolls, as a basis for clarifying the
inuence of roll radius on roughness transfer, for which the author
plans to report an experimental investigation in future. Here, the
same material, namely, an annealed carbon steel strip, is rolled
using two laboratory mills with different work roll radii. A numerical analysis, combining elasticplastic deformation of the material
and elastic deformation of the roll, is conducted to simulate the
experimental conditions using commercial FE software. The appropriateness of two simplied models, i.e., simple compression with
elastic roll and skin-pass rolling with a rigid circular roll, is also
discussed.
2. Experimental apparatus and FEM analysis
2.1. Experimental conditions
Experiments were carried out with two laboratory mills. As
shown in Fig. 1, one was a 2Hi mill with a work roll radius of
250 mm as an example of the operational size (hereinafter referred
to as large roll) and a 150 mm barrel width. The other was a 4Hi
mill with a work roll radius of 50 mm as an example of the laboratory size (hereinafter referred to as small roll) and 100 mm barrel
width. The roll material is high chromium steel, SUJ2 as provided
in JIS G 4805 (similar to AISI E52100), which was hardened and
tempered to HRC 65. The roll surface was ground to 0.2 m Ra.

Fig. 2. Schematic outline of skin-pass rolling model.

The workpiece is an annealed low carbon steel strip of which discontinuous yield behavior is practically negligible in order to ease
FEM calculations to obtain convergence. Its mechanical properties
were modeled as described in the next section. The dimensions of
the workpiece strips were thickness, h0 , 0.69 mm, length, 300 mm
and width, 80 mm and 50 mm, respectively for the large and small
rolls.
Before rolling, the roll and workpiece surfaces were both carefully degreased with petroleum benzin to achieve dry friction
conditions.
In order to measure elongation, the workpiece surface was
marked with two scratched lines in the cross-width direction, with
a spacing of 150 mm in the longitudinal direction. The distance
in the longitudinal direction was measured before and after the
experiment with a microscope equipped with a micrometer device.
The rolling velocity was 5 m per minute.
2.2. Conditions in FEM analysis
The FEM analysis simulating the experiments described above
was carried out by the two-dimensional, plane strain, static implicit
method in Abaqus standard ver.6 to predict the contact condition
and the deformation pattern. Fig. 2 shows a schematic outline of the
model. The upper half of the roll and the workpiece were modeled
considering the symmetry around the horizontal center line in the
workpiece thickness.
The central part of the roll corresponding to the half radius was
modeled as rigid to stabilize the analysis and to shorten the simulation time. The workpiece length in the FEM model was decided
to be more than 10 times the expected contact length which was
determined by preliminary analyses with a shorter model length.
Loading was modeled by applying a certain vertical downward displacement of the roll on the front tip of the workpiece in the rst
step. Thereafter, the roll was rotated around its center, which was
considered to be xed at the position of displacement.
The roll was modeled as an elastic body with Youngs modulus E = 205.8 GPa and Poissons ratio  = 0.3. The workpiece was
assumed to be elasticplastic with Youngs modulus E = 205.8 GPa,
Poissons ratio  = 0.3 and initial yield stress  0 = 165.8 MPa. Work
hardening was determined by connecting the dotted points on the
tensile test of the workpiece used in the experiment as shown in
Fig. 3. The Von Mises criterion was used. Adopting Coulombs law, a
friction coefcient of 0.3 was used to simulate the dry friction condition (Kijima and Bay, 2007). The contact problem between the
roll and the workpiece was solved adopting the penalty method
for normal penetration as well as tangential sliding (Kijima and
Bay, 2007).
The mesh for the workpiece was square and 1/16th the size of
the workpiece thickness. The mesh for the contact surface region of

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H. Kijima / Journal of Materials Processing Technology 213 (2013) 17641771

Yield stress [MPa]

500
400

Roll center

300

Rotation
Work roll

200
Rd

100
0

Rigid

0.02

0.04

0.06

0.08

0.1

0.12
h0/2

Equivalent plastic strain [-]

Workpiece
Elastic-plastic

z
x

Fig. 3. Work hardening model of material.

the roll was also square and twice the size of the workpiece mesh.
Rougher rectangular meshes were applied at distances further from
the contact surface. The element type of the roll was an 8-node
quadratic plane strain element (CPE8 in Abaqus) and that of the
workpiece was a 4-node bilinear, reduced integration plane strain
element with hourglass control (CPE4R in Abaqus).
Two additional cases were also modeled and analyzed to discuss
the characteristics of the contact condition and material deformation in skin-pass rolling. One was simple vertical compression by
the roll with the same vertical load as in skin-pass rolling, which
was modeled as vertical downward displacement of an elastic roll
(Pawelski et al., 1993), as shown in Fig. 4. The second used the conditions of a rigid circular roll with a certain attened radius Rd , which
was decided to approximate the thickness distribution in the roll
bite, as shown in Fig. 5. This case was added to evaluate the results
calculated with the rigid roll model in the previous papers. All the
analytical conditions except the rotational movement of the roll for
the rst case and the rigidity of the roll for the second case were
the same as those mentioned above.
3. Results and discussion
3.1. Comparison between experiment and analysis
Fig. 6, presented previously in Kijima, 2012b, shows the measured elongation from the experiment and the calculated results
from the FEM analysis of the rst model set up in Fig. 2,

Fig. 5. Schematic outline of skin-pass rolling model of rigid circular roll with certain
attened radius.

determined by the nominal strain in the longitudinal direction as

the average value in the through-thickness direction. The calculated values show good agreement with the experimental results
for both the large roll and the small roll. This result veries the
fact that the value of the friction coefcient, 0.3, is appropriate for
simulating the dry friction condition, and is the same as in plane
strain upsetting with small reduction (Kijima and Bay, 2007). The
appropriate coefcient might be changed in relation to the surface
roughness of the work roll, lubrication and rolling speed, and is
expected to affect the analytical results in the following sections.
Under these conditions, the relationships between rolling force
and elongation are rectilinear for both the large roll and the small
roll, but quantitatively, the results for the two rolls are quite different.
3.2. Inuence of roll radius on contact condition and material
deformation
Fig. 7 shows the calculated thickness distribution of the material and the corresponding elastically deformed shape of the roll
circumference. The zero point on the abscissa corresponds to the
position of the roll center. Approximated circular arcs, which will be
applied to describe the attened, rigid roll in the additional analysis in the following section, were also shown. Those arcs were
determined so that the entry and exit points and the minimum
thickness of the roll bite are the same as those under the elastic roll

Roll center
Work roll

z
h0/2

FEM
Experiment

Elongation [%]

Rigid
Elastic

R250 R50

Vertical
downward
displacement

R/2

Workpiece
Elastic-plastic

0
0

x
Fig. 4. Schematic outline of vertical compression model.

Rolling force [kN/mm]

Fig. 6. Relationship between rolling force and elongation (Kijima, 2012b).

H. Kijima / Journal of Materials Processing Technology 213 (2013) 17641771

Pressure p/ 0
Shear stress / 0 [-]

Plate thickness h/h0 [-]

1.005
1.000
0.995
0.990
0.44%
1.08%
2.11%
Elongation

0.985
0.980

Roll
Circular arc
Material

0.975
-4

-3

-2

-1

Elongation
2.11%
1.08%
0.44%

-3
In

Pressure p/ 0
Shear stress / 0 [-]

1.005
1.000
0.995
0.990

2
1.5

1.75%
1.12%
0.32%

0.980

-1

Rolling direction x/h 0 [-]

Out

Roll
Circular arc

Elongation
Pressure

1
0.5
0

-0.5

0.985

-2

(a) Large roll

2.5

(a) Large roll

0.32%
1.12%
1.75%
Elongation

Pressure

Shear stress
-4

In  Rolling direction x/h0 [-]  Out

Plate thickness h/h 0 [-]

8
7
6
5
4
3
2
1
0
-1
-2

1767

Shear stress

-1
-1

-1.5

Material

0.975

In

-0.5

Rolling direction x/h 0 [-]

0.5
Out

(b) Small roll

-1.5

-1

-0.5

0.5

In  Rolling direction x/h 0 [-]  Out

(b) Small roll

Fig. 7. Calculated thickness distribution, corresponding deformed roll circumference and approximated circular arc, (a) large roll, (b) small roll.

condition. The radii of the arcs are listed in Table 1 as ratios to the
original radius.
No intrusion of the roll surface into the material can be seen
under any conditions. Characteristic deformation patterns can be
seen for the large roll (Sun et al., 2009), as a certain concavity occurs
around the center of the roll bite. On the other hand, the deformed
circumference of the small roll remains circular.
Fig. 8 shows the distribution of the normal pressure and the
shear stress on the contact surface, and Fig. 9 shows its ratio as
determined by the shear stress over the normal pressure. This ratio
implies a nominal friction coefcient. The region for the absolute
friction coefcient value of 0.3, which is same as the input value
of Coulomb friction, is the sliding region, and the area for friction
coefcients <0.3 is the sticking region (Peric and Owen, 1992).

Table 1
Radius of approximated circular arcs.
Roll radius R (mm)

250 (Large roll)

Elongation (%)
Flattened radius Rd/R ()

0.44
3.26

1.08
3.51

2.11
3.95

50 (Small roll)

Elongation (%)
Flattened radius Rd/R ()

0.32
1.53

1.12
1.33

1.75
1.33

Fig. 8. Normal pressure and shear stress distribution at interface between material
and roll ( 0 : initial yield stress, 165.8 MPa), (a) large roll, (b) small roll.

The pressure distributions for the large roll are a type of friction
hill, even for the small elongation of 0.44%. The point of peak pressure corresponds to the concavity of the elastic deformation of the
roll. Sliding regions exist at the entry and exit, and a large sticking
region exists in the center of the roll bite. Inside the sticking region,
the shear stress distribution gradually transfers to the opposite
direction. These tendencies coincide with plane strain upsetting
with small reduction as reported by Kijima and Bay (2006, 2007).
On the other hand, the pressure distributions for the small roll
are quite different from the above-mentioned friction hill. The peak
pressure exists at the entry region. The sliding region at the entry
side is quite short, and most of the entry side is in the sticking
region. The absolute values of the pressure and the contact length
are both much smaller than those of the large roll.
To clarify the difference in the material deformation patterns,
the distributions of plastic strain in the rolling direction and equivalent plastic strain on the material surface and on the symmetry
center in the thickness direction are shown in Figs. 10 and 11.
In all cases, surface plastic strain in the rolling direction
increases earlier than plastic strain at the center. The two lines for
the surface and the center cross inside the sticking region. Their
values at the exit are almost the same for each case. On the other
hand, the distribution of equivalent plastic strain is quite different,
depending on the roll radius. In the case of the large roll, the equivalent plastic strain on the surface increases steeply after zero on
the abscissa and becomes much larger at the exit than the equivalent plastic strain at the center and the plastic strain in the rolling
direction. This implies that some additional shear strain occurs,
especially in the surface region. In the case of the small roll, the

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H. Kijima / Journal of Materials Processing Technology 213 (2013) 17641771

0.07

atio of shear/press ure [ ]

0.4
0.3

Elongation
2.11%
1.08%
0.44%

0.2
0.1

0.06
0.05
0.04

0.0

0.03

-0.1

Elongation

Surface
Center

2.11%

0.02

-0.2
-0.3

0.01

-0.4

-4

-3

In

-2

-1

Rolling direction x/h 0 [-]

1.08%
0.44%
-4

-3
In

Out

-2

-1

Rolling direction x/h 0 [-]

Out

(a) Large roll

(a) Large roll

0.025

0.4
0.3

Elongation
Surface
Center

0.02

0.2
0.1

1.75%

0.015

1.12%

0
0.01

Elongation
1.75%
1.12%
0.32%

-0.1
-0.2
-0.3

-0.4
-1.5

-1
In

-0.5

0.5

Rolling direction x/h 0 [-]

Plastic strain
in rolling direction [-]

0.025
2.11%

Surface
Center

0.015

1.08%

0.01
0.005

0.44%
Elongation

0
-4

-3
In

-2

-1

Rolling direction x/h 0 [-]

Out

(a) Large roll

0.025
Elongation
1.75%

0.02
Surface
Center

0.015

1.12%
0.01
0.32%

0.005
0
-1.5

-1
In

-0.5

-1

-0.5

Rolling direction x/h 0 [-]

0.5
Out

(b) Small roll

Fig. 9. Ratio between shear stress and normal pressure as nominal friction coefcient, (a) large roll, (b) small roll.

0.02

-1.5
In

Out

(b) Small roll

Plastic strain
in rolling direction [-]

0.32%

0.005

Rolling direction x/h 0 [-]

0.5
Out

(b) Small roll

Fig. 10. Plastic strain in rolling direction on material surface and central symmetry
line, (a) large roll, (b) small roll.

Fig. 11. Equivalent plastic strain on material surface and central symmetry line, (a)
large roll, (b) small roll.

distribution of the equivalent plastic strain resembles that of the

plastic strain in rolling direction. Therefore, the value at the exit for
the small roll is almost the same on the surface and at the center
for the each elongation, implying that the additional shear strain is
much less than that with the large roll and occurs almost uniformly
in the through-thickness direction.
3.3. Inhomogeneity of workpiece deformation
Fig. 12 shows the calculated deformed shape of the originally
vertical cross section before the roll bite for elongation of ca. 1.1%.
The lateral position at the axis of symmetry is the reference. The
shape of each line is exaggerated 200 times in the rolling direction
(Kijima and Bay, 2006, 2007). In Fig. 12b, the shape in the case of
the large roll in Fig. 12a is also shown corresponding to the range
on the abscissa. The shape displays inhomogeneous deformation, in
contrast to the hypothesis of the slab method in the classical rolling
theory. Additional shear strain can be recognized as leaning from
the vertical, straight line.
The differences of equivalent plastic strain in the surface and the
center region in Fig. 11a and b can be explained from the deformed
shape of the vertical cross section in Fig. 12. In the case of the large
roll, the change in the leaning angle can be seen in the surface
region, where the equivalent strain is larger than at the center, to
the right and returning back to almost vertical. Actually, the lines of
the cross section remain almost straight and vertical near the symmetry center throughout the roll bite. In contrast to this, in the case
of the small roll, the line of the cross section leans almost uniformly
around the center of the roll bite and returns to a nearly straight line
at the exit. Considering the difference of the range in the abscissa,
the deformation of the small roll is smaller than that of the large

0.5

0.3
0.2
0.1

Center
-4

In

-3

-2

-1

Rolling direction x/h0 [-]

6
5

Skin-pass
Compress
Hertzian

4
3
2
1

Out

(a) Large roll

Vertical direction z/h0 [-]

Elongation
2.11%
1.08%
0.44%

0.4

1769

Surface

Pressure p/ 0 [-]

Vertical direction z/h0 [-]

H. Kijima / Journal of Materials Processing Technology 213 (2013) 17641771

0.5

-4

Surface

-3
In

0.4

-2

-1

Rolling direction x/h 0 [-]

Out

Fig. 14. Pressure distribution in skin-pass rolling, simple compression and Hertzian
elastic contact (Kijima, 2012c).

0.3
0.2
0.1
0
-1.5

Center
-1

In

-0.5

0.5

Rolling direction x/h0 [-]

Out

(b) Small roll

Fig. 12. Shape of cross section (Kijima, 2012a,b) (h0 : initial thickness, 0.69 mm, z:
vertical position in thickness from the center), (a) large roll, (b) small roll (gray: large
roll in (a)).

xz/ 0

[-]

0.8
0.6
0.4
0.2
0
-0.2
-0.4
-0.6
-0.8
-1

3h0/8
h0/4
h0/8
Surface
-4

-3
In

-2

-1

Rolling direction x/h 0 [-]

Shear stress

Shear stress

xz /

0 [-]

roll. This is considered to be the reason for the smaller difference of

equivalent plastic strain after rolling in the surface and the center
in Fig. 11b compared to the large roll in Fig. 11a.
Fig. 13 shows the shear stress distributions inside the workpiece for elongation of ca. 1.1%. Even with an inhomogeneity in the

deformation, the tendency of the distribution is the same throughout the thickness for the large roll, resulting in the pressure
distribution, as shown in Fig. 8, of the typical friction hill. On the
other hand, the shear stress distributions are quite different for
the small roll. The point of the peak pressure seems to correspond
to the point where the shear stress distribution inside the workpiece crosses the zero line. Although the rolling condition is quite
different, a similar pressure distribution was experimentally measured under a condition of small contact length to average thickness
(Motomura and Shimamura, 1975).
Considering these contact conditions and material deformation
pattern, the experimental skin-pass rolling with small radius rolls
is not appropriate for simulating skin-pass rolling in operation with
large radius rolls. Actually, the rolling condition with the large roll
in this study belongs to the second category (Fleck et al., 1992), in
which an increased deformation of the roll occurs near the center of

0.4
0.3
0.2
0.1
0
-0.1
-0.2
-0.3
-0.4
-0.5

3h 0/8
h0/4
h0/8
Surface
-1.5

-1
In

Out

-0.5

Rolling direction x/h 0 [-]

(b) Small roll

(a) Large roll

Contact region

h0/2

Surface
h0/8
h0/4
3h0/8
Center

(c) Lines of data

Fig. 13. Shear stress distribution inside the workpiece, (a) large roll, (b) small roll, (c) lines of data.

0.5
Out

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H. Kijima / Journal of Materials Processing Technology 213 (2013) 17641771

Vertical direction z/h 0 [-]

Peak pressure p/ 0 [-]

Surface

0.5

8
7
6
5
4
3

Skin-pass rolling
Compression
Hertzian contact

2
1

0.4
0.3

Rg.
El.

0.2
0.1

Center

0
-4

-3

In

Rolling / compression force [kN/mm]

-2

-1

Rolling direction x/h0 [-]

Out

Fig. 17. Shape of cross section for elongation of 1.08% (h0 : initial thickness, 0.69 mm,
z: vertical position in thickness from the center).

Fig. 15. Comparison of peak pressure.

3.4. Simplication of analysis

Pressure p/ 0
Shear stress / 0 [-]

3.4.1. Simple compression

Fig. 14 shows the calculated pressure distribution for skin-pass
rolling with the large roll and simple compression with the same
elastic roll. The pressure distributions of the Hertzian elastic contact
of the roll on a rigid, at surface are also drawn. The compression
load and the Hertzian contact load are the same as the skin-pass
rolling conditions. The position on the abscissa for simple compression is adjusted so that the left-hand side of the distribution
almost matches that of skin-pass rolling. The peak pressure values
are compared in Fig. 15.
The pressure distribution in skin-pass rolling can be satisfactorily approximated by simple compression with the same load.
This is a great aid in reducing the burden of simulating skin-pass
rolling conditions just to know the approximate pressure distribution. In addition, the Hertzian theory provides the value of peak
pressure with certain precision. This is due to the fact that, considering the characteristics of skin-pass rolling conditions, the pressure
distribution is largely dominated by the elastic deformation of the

8
7
6
5
4
3
2
1
0
-1
-2

Rigid
Elastic

Elongation
2.11%
1.08%
0.44%

Pressure

Shear stress
-4
In

-3

-2

-1

Rolling direction x/h 0 [-]

Out

Fig. 16. Effect of simplication of rigid roll on stress distribution.

3.4.2. Rigid roll model

Fig. 16 shows the pressure and shear stress distributions for the
rigid roll condition of the large roll shown in Fig. 8, in comparison
with the elastic roll condition. In Figs. 17 and 18, the deformation
pattern of the vertical cross section and the equivalent plastic deformation for the elongation of 1.08% are compared respectively as
Figs. 12 and 11. The calculated elongation and rolling force coincide with the elastic roll in each case. Considering these results,
even with the admitted difference in thickness distribution, due
to the characteristic concave shape of the elastic deformation of
the roll, it is obviously reasonable to simplify the analysis with a
rigid, circular roll determined to be the same contact length and
the minimum thickness. Actually, when the author calculated various additional conditions, the contact length is dominant for the
rolling force under a certain elongation condition, and the minimum thickness is the important parameter for elongation. In other
words, the thickness distribution is not crucial to the contact condition and material deformation. Hence, the previously calculated
results with a rigid circular roll in the literature could be accepted
qualitatively (Kijima and Bay, 2007).

Equivalent plas tic s train [-]

the roll bite, while that with the small roll belongs to the rst category, in which the deformed circumference of the work roll remains
circular. The basic mechanisms in workpiece deformation observed
in the large roll skin-passing, as regards the contact condition and
deformation pattern, especially the large plastic strain in the surface region, are qualitatively similar to plane strain upsetting with
small reduction (Kijima and Bay, 2006, 2007).

roll, as the thickness change in the roll bite is quite small compared
to the contact length in skin-pass rolling. This simplication will be
utilized to clarify the inuence of roll radius on roughness transfer,
for which the author plans to report an experimental investigation
in the future. For that purpose, the interactions and local deformation of the asperities will be one of the key parameters which need
to be added to the analysis (Dixon and Yuen, 2006).

0.02

Rigid
Elastic

0.015

Surface

0.01

Center

0.005
0
-3

-4
In

-2

-1

Rolling direction x/h 0 [-]

3
Out

Fig. 18. Difference of equivalent plastic strain by roll model.

H. Kijima / Journal of Materials Processing Technology 213 (2013) 17641771

1771

4. Conclusion

Appendix A. Supplementary data

The inuence of roll radius on the contact condition and material

deformation in skin-pass rolling was investigated experimentally
and analytically. Experimental skin-pass rolling with two laboratory mills was conducted with the same workpiece and two
different work roll radii under a dry friction condition to investigate
the effect of roll size. In one case, the roll radius corresponded to
the size in operational mills, and in the other, the radius was a size
used in laboratory mills. FEM analysis, which was performed using a
commercial software program and combining elasticplastic deformation of the workpiece and elastic deformation of the roll, showed
good agreement with the experimental results. Under these conditions, the relationships between rolling force and elongation are
rectilinear for both the large roll and the small roll, but the results
with the two roll sizes are quantitatively quite different.
With the large roll, a friction hill shape of pressure distribution is
shown, and a central sticking region and two sliding regions at the
entry and exit exist, as estimated by an investigation of plane strain
upsetting with small reduction. With the small roll, the contact condition is quite different, as are the absolute values of the pressure
and the contact length. The pressure peak occurs at the entry and
the sliding region at the exit is quite short. The difference in material deformation was claried by the plastic strain distribution and
deformation pattern of the vertical cross section. With the large roll,
additional shear strain concentrates in the surface region, whereas
more uniform plastic strain occurs in the through-thickness direction at the exit in the case of the small roll. Considering such
differences, it can be concluded that the experimental skin-pass
rolling with the small radius roll is not appropriate for simulating
skin-pass rolling in actual operation.
Considering the characteristics of skin-pass rolling, two simplications were calculated. The pressure distribution in skin-pass
rolling can be approximated by simple compression of an elastic roll
with the same load. Moreover, the peak pressure can be estimated
by the Hertzian theory of elastic contact on a rigid, at surface.
This simplication is benecial for reducing the burden of analysis.
A rigid, circular roll model, in which the radius is decided so that
the entry and the exit point and the minimum thickness inside the
roll bite are the same as those under the elastic roll condition, was
also calculated. Even with the admitted difference in the thickness
distribution, it is quite reasonable to simplify the analysis using
the rigid, circular roll. This implies that the contact length and the
minimum thickness are the important parameters and the thickness distribution is not crucial to the contact condition and material
deformation.

Supplementary data associated with this article can be found, in

the online version, at http://dx.doi.org/10.1016/j.jmatprotec.2013.
04.011.
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