An elasto-plasto-hydrodynamic model of strip rolling with oil/water emulsion lubricant

We review the problem of metalworking lubrication and include the hitherto much neglected elastic deformation in our analysis. This analysis is carried out for both pure oil lubricant and for lubrication with oil-in-water emulsion. For the latter, we make use of the extended Reynolds equations of Al-Sharif et al. (Ph.D. dissertation, University of Pittsburgh, 1992), which were derived for lubrication with binary mixtures of Newtonian fluids. The results of this paper demonstrate several experimentally observed phenomena of metalworking lubrication, the most significant being that an increase in the value of the elastic modulus enhances oil pooling ahead of the roll bite and results in a thicker film in the working zone. (C) 2003 Elsevier Ltd. All rights reserved.