冷轧铜合金乳化液润滑模型及表面质量研究（英文）

Research of Lubrication Model and Surface Quality in Cold-Rolling Copper Alloy Using O/W Emulsions

根据平均流量模型和微凸体模型建立了冷轧铜合金混合润滑状态的理论模型。计算了使用不同运动粘度的乳化油,不同初始油相浓度的乳化液和在不同压下率条件下,轧制变形区的油相浓度,流动压力和接触面积。由计算结果可知,在冷轧过程中为使乳化液起到好的润滑作用和冷却效果,乳化油的运动粘度选在40-50 mm2/s之间,乳化液的初始油相浓度选在在0.02-0.05之间,道次压下率选择在30%。为进一步验证模型,利用四球摩擦磨损试验检测了乳化液的最大无卡咬负荷,确定乳化油的运动粘度和乳化液的初始油相浓度;通过观察轧后铜合金表面形貌确定轧制道次压下率,通过实验研究发现,实验结果和计算结果一致,验证了模型的准确性。乳化液润滑模型为轧制过程中乳化油运动粘度、乳化液初始油相浓度和道次压下率的选择提供了参考依据。

A theoretical model for cold-rolling copper alloy in mixed lubrication regime was developed based on the average volume flow model and asperity flattening model. The developed scheme was able to calculate oil concentration λd at any point within work zone, lubricant pressure, contact area ratio and film thickness ratio with different oil viscosity, pass reduction and the initial oil concentration λds. According to the lubrication model, for getting good lubrication and cooling effect of emulsions in rolling process, the rolling oil viscosity was selected in the range from 40 mm2/s to 50 mm2/s, the pass reduction about 30% and the initial oil concentration λds of emulsion in the range from 0.02 to 0.05. For verifying the lubrication model, the last nonseizure load was tested by the four-ball tests to confirm oil viscosity and initial oil concentration, and the rolled copper alloy surface topographies were analyzed to confirm pass reduction. The results show that the calculation data agree well with the measured data from experiment. They provide technical references for selecting rolling process parameters and emulsions.