Numerical mapping of the surface roughness during skin pass rolling of high strength aluminum alloys using the plane strain upsetting test
Lena Koch, Min Chen, Holger Brüggemann, David Bailly, Emad Scharifi
Abstract. Skin-pass rolling is an important process for setting the surface quality of high strength aluminium alloys. This study presents a plane-strain upsetting numerical model to approximate the skin-pass rolling process by simulating an imprinting interaction between die and a strip of a precipitation-hardening EN AW-6016 aluminium alloy after cold rolling passes and considering several simplifications. The die surface is modeled using circular arcs corresponding to a defined roughness parameter Ra to analyze the roughness transfer. Results indicate that the coefficient of friction in the upsetting model affects the distribution of sticking and sliding zones, while it does not significantly impact roughness transfer. Roughness transfer is primarily determined by the surface profile of the die and the relative motion between the die and the strip, with greater distances between circular arcs resulting in higher transfer rates. The upsetting model demonstrates lower complexity and faster computation times compared to the macro-meso model, underlining its potential for efficient preliminary analyses.
Keywords
Aluminum, FEM, Skin-Pass Rolling, Roughness
Published online 5/7/2025, 8 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Lena Koch, Min Chen, Holger Brüggemann, David Bailly, Emad Scharifi, Numerical mapping of the surface roughness during skin pass rolling of high strength aluminum alloys using the plane strain upsetting test, Materials Research Proceedings, Vol. 54, pp 909-916, 2025
DOI: https://doi.org/10.21741/9781644903599-97
The article was published as article 97 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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