The purpose of this paper is to conduct a comprehensive experimental study to achieve optimal surface roughness of aluminum rolled with freshly ground rollers of two high rolling mills.
Various rolling oils and processing conditions are applied in the rolling process. Resultant surface roughness is measured with a profilometer; and surface topography of aluminum after rolling is observed under scanning electron microscope. In order to examine the oil film thickness (the most critical factor in rolling process), a planimeter is used to measure the area of oil patch resulting from a precisely controlled oil droplet, which in turn allows calculation of outlet oil film thickness as an approximation to inlet oil film thickness in the deformation region.
The experimental results indicate that two major factors have dominant impacts on aluminum's surface roughness in the rolling lubrication process: reduction of roller; and viscosity of lubrication oil. Based upon analysis of the experimental data, optimal roller reduction is found to be within range (23%, 30%) and optimal oil viscosity should be chosen, such that the ratio between inlet oil film thickness in the deformation region and the combined surface roughness is around 1.
According to the authors' observations, the above parameter choices generally assure excellent surface quality of aluminum after rolling.
