Simulating the use of lubricants duriong cold rolling : modelling the interdependence between lubricant properties and rolling performance : final report

The main aim of this project was to develop and evaluate testing methods for the technological performance of cold rolling lubricants. These methods would allow a better founded decision on which lubricant is best suited for a certain appncation. Furthermore, the aim was to identify and quantify the most decisive parameters for product quality in cold rolling, expressed in terms of surface cleanliness, and to set up a model for the evolution of surface cleanliness which could be used to improve the operation of cold rolling mills. The information included as input data in the cleanliness model was extracted from empirical data obtained on an industrial production line. MARS was the technique selected to develop a 'black box' model. ln a first step, a model was developed using only rolling parameters. The accuracy of the model was good, but it did not fit cleanliness variation over longer periods of time. When additional variables, calculated fram emulsion parameters, were introduced, the success rate of the model could be significantly improved. Different laboratory testing methods have been employed for evaluating the lubricating performance and the annealing properties of fresh and aged rolling oils. The results were validated by comparison with industrial results and detailed chemical and surface chemical analyses. Ageing and mixing properties of rolling oil emulsions were tested using laboratory and pilot tests. The properties of the emulsions were compared to properties of industrial samples. The results were well transferable, which means that the ageing and mixing mechanisms in industrial cold rolling emulsions can be simulated in small-scale laboratory tests.