Finite element method analysis of surface roughness transfer in micro flexible rolling

Micro flexible rolling aims to fabricate submillimeter thick strips with varying thickness profile, where the surface quality of products is mainly determined by initial workpiece surface roughness and subsequent surface asperity flattening process, which is affected by process parameters during rolling. This paper shows a 3D finite element model for flexible rolling of a 250 μm thick workpiece with reduction of 20 to 50%, and rolling phase with thinner thickness indicates a better ability to decrease the surface roughness. Four types of initial workpiece surface roughness are studied in the simulation, and the influences of process parameters, such as friction coefficient, rolling speed and roll gap adjusting speed, on surface asperity flattening of workpieces with different initial surface roughness have been numerically investigated and analysed.