Applying mathematical models and numerical methods is crucial for describing and simulating the metal cold-rolling process, wherein the accurate prediction of rolling force is an effective way to improve the quality of rolled sheets. This paper considers key influencing parameters such as friction lubrication, stress, tension, and roll-flattening radius during the rolling process and establishes a calculation model for the friction coefficient and roll-flattening radius. By considering the coupling effect of the dynamic roll gap on rolling force, a rolling force model for non-steady-state friction lubrication during the rolling process is obtained. The correctness of the proposed model is verified by comparing it with industrial measurement results. The influences of the friction coefficient, stress, tension before and after rolling, and roll-flattening radius on rolling force are quantitatively studied. The results show that the rolling force increases with an increase in the friction coefficient. When the friction coefficient exceeds 0.2, the rate of increase slows down, approaching dry friction conditions. The rolling force increases linearly with stress but decreases with increasing tension before and after rolling. The rolling force model, considering the roll-flattening radius, provides numerical calculation results that are closer to an industrial measured rolling force. This work contributes to a better understanding of the mechanism behind the improvement of the cold rolling process.

The study of the influence of the nanoparticle volume fraction and aspect ratio of microchannels on the fluid flow and heat transfer characteristics of nanofluids in microchannels is important in the optimal design of heat dissipation systems with high heat flux. In this work, the computational fluid dynamics method was adopted to simulate the flow and heat transfer characteristics of two types of water-Al₂O₃ nanofluids with two different volume fractions and five types of microchannel heat sinks with different aspect ratios. Results showed that increasing the nanoparticle volume fraction reduced the average temperature of the heat transfer interface and thereby improved the heat transfer capacity of the nanofluids. Meanwhile, the increase of the nanoparticle volume fraction led to a considerable increase in the pumping power of the system. Increasing the aspect ratio of the microchannel effectively improved the heat transfer capacity of the heat sink. Moreover, increasing the aspect ratio effectively reduced the average temperature of the heating surface of the heat sink without significantly increasing the flow resistance loss. When the aspect ratio exceeded 30, the heat transfer coefficient did not increase with the increase of the aspect ratio. The results of this work may offer guiding significance for the optimal design of high heat flux microchannel heat sinks.

To reveal the influence of surface morphology characteristics in mixed lubrication on the contact characteristics of the rolling interface, a random three-dimensional rough surface model based on Gaussian distribution theory was established. The model utilizes the finite element method (FEM) to simulate the regular contact and tangential sliding behavior of micro-asperities at the rolling interface in mixed lubrication conditions. The connection bearing capacity of models with varied roughness in mixed lubrication was studied. Furthermore, the effect of various sliding and normal indentation amounts on the normal and friction stress was investigated. The simulation result reveals that the roughness of the surface influences the distribution of the lubricating oil film. The lubricating oil layer between the interfaces with a lower roughness has a higher bearing capacity due to its more uniform distribution of peaks and valleys. An increase in the normal indentation amount raises the friction stress and normal stress. In contrast, an increase in sliding lowers the normal pressure, substantially impacting the fluctuation of the friction coefficient dramatically. Finally, the random three-dimensional rough surface model is verified by comparing it with the experimental data in the related literature.

The study of the influence of the nanoparticle volume fraction and aspect ratio of microchannels on the fluid flow and heat transfer characteristics of nanofluids in microchannels is important in the optimal design of heat dissipation systems with high heat flux. In this work, the computational fluid dynamics method was adopted to simulate the flow and heat transfer characteristics of two types of water–Al2O3 nanofluids with two different volume fractions and five types of microchannel heat sinks with different aspect ratios. Results showed that increasing the nanoparticle volume fraction reduced the average temperature of the liquid–solid heat transfer surface and thereby improved the heat transfer capacity of the nanofluids. Meanwhile, the increase of the nanoparticle volume fraction led to a considerable increase in the pumping power of the system. Changing the aspect ratio of the microchannel effectively improved the heat transfer capacity of the heat sink. Moreover, increasing the aspect ratio effectively reduced the average temperature of the heating surface of the heat sink without significantly increasing the flow resistance loss. When the aspect ratio exceeded 30, the heat transfer coefficient did not increase with the increase of the aspect ratio. The results of this work may offer guiding significance for the optimal design of high heat flux microchannel heat sinks.

Utilizing the average Reynolds equation, lubrication friction theory, metal rolling deformation theory, and temperature energy theory, a multi-parameter-coupling mixed lubrication model considering the influence of surface roughness with Gaussian distribution characteristics under rolling conditions was established. The results show that the stress distribution of the lubricating oil at the rolling interface conforms to the typical characteristics of line contact stress distribution. The oil film pressure does not increase significantly with the increase in the reduction ratio. A second peak pressure appears before the outlet. The second peak pressure reaches its maximum when ε = 0.2. The rolling speed has little effect on oil film pressure, but greatly affects oil film thickness. The influence of rolling speed mainly occurs in the outlet zone and at the second peak pressure location. The oil film thickness increases with rolling speed. During rolling, the temperature rise in the rolls exhibits two peak values. The first peak appears near the neutral point, and the second peak appears near the outlet, which is also where the second peak pressure is located. The influence of temperature will reduce the peak stress on the rolls. The overall stress on the rolls will also decrease.