Effect of material thickness and reduction ratio on roughness transfer in skin-pass rolling to DC04 grade sheet materials

Purpose The last stage of the cold rolling process is skin-pass rolling and one of its most significant goals is to obtain appropriate topography on the surface of the sheet steel used extensively such as in automotive industry. The purpose of this paper is to investigate the effect of thickness change and various reduction ratios on roughness transfer of DC04 grade sheet material. Design/methodology/approach DC04 grade sheet materials with different reduction ratios and several thicknesses were subjected to skin-pass rolling process in the rolling equipment with a two-high roll. Some roughness parameters were determined as a result of roughness measurements from the surfaces of roughened sheet materials. Findings While the roughness transfer is higher in 1-mm thick material in reduction ratios up to 430 micrometers; in reduction ratios above 430 micrometers, it is higher for 1.5-mm thick materials. As the reduction ratio increases in DC04 grade sheet materials, the homogeneity of the roughness distribution in 1-mm thickness sheet material deteriorates, while the roughness distribution in 1.5-mm thickness sheet material is more homogeneous. Originality/value This paper demonstrates how material thickness and reduction ratio affect the roughness transfer in skin-pass rolling. The results obtained can be used by optimizing in manufacturing processes.