Empirical Roll Wear Model to Predict Changes of the Roll Surface Height Distribution in a Temper Rolling Process

Understanding the wear behavior of the work rolls in a temper rolling or cold rolling process is crucial to model the surface profile transfer onto the rolled strip. Although roll wear has been extensively studied, its dynamics during the processing of zinc-coated materials are not yet fully understood. Zinc adhesion on the roll surface can significantly influence the measured height profiles. A novel empirical roll wear model predicts the surface height distribution as a function of the rolled length. The model accounts for the dominant material removal and also includes material transfer through smearing or zinc adhesion. The model preserves maximal statistical surface information, while being computable sufficiently quickly for realtime applications. A displacement interpolation method from optimal transport (OT) theory is adapted to approximate measured height distributions. Experimental validation, based on data from an industrial temper rolling process, demonstrates that the model accurately predicts both the evolution of the height distribution and the arithmetic mean roughness R a .