Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21B—ROLLING OF METAL
  • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
  • B21B1/22—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length
  • B21B1/227—Surface roughening or texturing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21B—ROLLING OF METAL
  • B21B27/00—Rolls, roll alloys or roll fabrication; Lubricating, cooling or heating rolls while in use
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21B—ROLLING OF METAL
  • B21B27/00—Rolls, roll alloys or roll fabrication; Lubricating, cooling or heating rolls while in use
  • B21B27/005—Rolls with a roughened or textured surface; Methods for making same
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21B—ROLLING OF METAL
  • B21B3/00—Rolling materials of special alloys so far as the composition of the alloy requires or permits special rolling methods or sequences ; Rolling of aluminium, copper, zinc or other non-ferrous metals
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D51/00—Making hollow objects
  • B21D51/16—Making hollow objects characterised by the use of the objects
  • B21D51/26—Making hollow objects characterised by the use of the objects cans or tins; Closing same in a permanent manner
  • B21D51/2607—Locally embossing the walls of formed can bodies
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21B—ROLLING OF METAL
  • B21B3/00—Rolling materials of special alloys so far as the composition of the alloy requires or permits special rolling methods or sequences ; Rolling of aluminium, copper, zinc or other non-ferrous metals
  • B21B2003/001—Aluminium or its alloys
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21B—ROLLING OF METAL
  • B21B2261/00—Product parameters
  • B21B2261/14—Roughness
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21B—ROLLING OF METAL
  • B21B2267/00—Roll parameters
  • B21B2267/10—Roughness of roll surface

Definitions

• the present disclosure relates generally to work rolls for metal rolling. More specifically, but not by way of limitation, this disclosure relates to a textured work roll for applying a gloss finish on a metal substrate during rolling and methods for texturing a work roll for applying a gloss finish on a metal substrate.
• Metal rolling can be used for forming metal strips from stock, such as ingots or thicker metal strips.
• Metal rolling can involve a metal strip or substrate (e.g., aluminum or other metal material) passing between a pair of work rolls of a mill stand and the pair of work rolls can apply pressure to reduce the thickness of the metal strip.
• a metal strip or substrate e.g., aluminum or other metal material
• a texture of a work roll used to roll a metal substrate may be an important factor in the performance of a metal rolling operation and the final material properties of the rolled metal substrate.
• a finely polished or smooth work roll may not be able to provide sufficient friction to grip the metal strip during rolling operations.
• a work roll with a relatively rough texture may be limited to small reductions in thickness of the metal strip to avoid transferring an undesirable surface finish to the metal strip and generating unacceptable levels of debris due to the tendency for projections of the rough surface texture on the work roll to break off during processing.
• Various techniques may be used to modify the surface finish and/or surface texture of a work roll. Many work roll texturing processes may increase the surface roughness of the work roll to a degree that can impact the quality and efficiency of the rolling process. It may be desirable to texture a work roll for imparting a desirable texture on a metal strip.
• Certain aspects and features of the present disclosure relate to texturing a work roll for applying an isotropic gloss finish on a metal substrate (e.g., a metal sheet or plate) during a rolling process and a textured work roll for applying the isotropic gloss finish on a metal substrate.
• the metal substrate can be an aluminum sheet or an aluminum alloy sheet.
• a gloss finish can refer to a relatively uniform glossiness with a slightly matted appearance on a surface of the metal substrate.
• a metal substrate with a gloss finish can have uniform glossiness and an isotropic surface (e.g., a surface that is substantially identical in all directions) with minimal directionality.
• a work roll e.g., a cold mill work roll
• the work roll can be textured by grinding or polishing the work roll and/or by electro-discharge texturing (“EDT”) techniques.
• EDT electro-discharge texturing
• a combination of techniques can be used to texture the work roll for applying a gloss finish on a surface of a metal substrate.
• a work roll can be textured by grinding a surface of the work roll to reduce a roughness of the surface and form a ground work roll surface.
• the ground work roll surface can have a surface roughness (Ra) value from approximately 0.2 ⁇ m to approximately 0.5 ⁇ m.
• the ground work roll can have an Ra value from approximately 0.3 ⁇ m to approximately 0.5 ⁇ m.
• the ground work roll surface can have a skewness (Rsk) value from approximately -1.5 to approximately 0.5.
• various EDT techniques can be used to texture the ground work roll surface to form an EDT work roll surface.
• the EDT work roll surface can have an Ra value from approximately 0.5 ⁇ m to approximately 1.0 ⁇ m. In another example, the EDT work roll surface can have an Ra value from approximately 0.5 ⁇ m to approximately 0.8 ⁇ m. The EDT work roll surface can have an Rsk value from approximately -1.0 to approximately 1.0. The EDT work roll surface may also have a peak count (Pc) from approximately 80/cm to approximately 140/cm. In some examples, the EDT work roll surface can be an isotropic surface with minimal directionality. The EDT work roll surface can be polished to reduce a roughness of the EDT work roll surface and form a polished work roll surface. The polished work roll surface can have an Ra value from approximately 0.3 ⁇ m to approximately 0.7 ⁇ m.
• the polished work roll surface can also have an Rsk value from approximately -3.0 to approximately 0.0.
• the polished work roll surface may also have a Pc from approximately 100/cm to approximately 180/cm.
• the polished work roll surface having an Ra value between approximately 0.3 ⁇ m and approximately 0.7 ⁇ m can be used to apply a gloss finish on a metal substrate.
• a work roll having a polished work roll surface with an Ra value between approximately 0.3 ⁇ m and approximately 0.7 ⁇ m can be used in a cold mill for cold rolling the metal substrate to apply a gloss finish on the metal substrate.
• Cold rolling the metal substrate using a polished work roll with an Ra value between approximately 0.30 ⁇ m and approximately 0.70 ⁇ m can cause the metal substrate to have enhanced characteristics, including, for example, increased resistance to high pressure, reduced friction, or increased lubricant retention.
• FIG. 1A is a schematic perspective view of a ground work roll surface according to one example.
• FIG. 1E is a schematic perspective view of the surface texture of the work roll surface of FIG. 1C undergoing polishing.
• FIG. 1F is a schematic perspective view of the work roll surface of FIG. 1E after polishing.
• FIG. 1G is a graph depicting the roughness of the work roll surface of FIG. 1F.
• FIG. 3 is a flow chart depicting an example of a process for texturing a work roll that can be used to apply a gloss finish on a metal substrate, according to one example of the present disclosure.
• FIG. 4 is a flow chart depicting an example of a process for applying a gloss finish on a metal substrate using a polished work roll, according to one example of the present disclosure.
• the work roll can then be further processed with electro-discharge texturing to produce an isotropic surface texture with minimum directionality and an Ra value from about 0.50 ⁇ m to about 1.0 ⁇ m.
• the work roll can be processed with electro-discharge texturing to produce an isotropic texture with minimum directionality and an Ra value from about 0.50 ⁇ m to about 0.8 ⁇ m.
• the isotropic surface texture may also have an Rsk value from about -1.0 to about 1.0 or a Pc from approximately 80/cm to approximately 140/cm.
• the work roll, now with an isotropic surface texture may be polished to form a work roll surface having an Ra value from about 0.30 ⁇ m to about 0.70 ⁇ m.
• the texture of the work roll surface may also have an Rsk value from approximately -3.0 to approximately 0.0 or a Pc from about 100/cm to about 180/cm.
• Another exemplary method of applying an isotropic gloss finish on a metal substrate includes: grinding an unfinished work roll to form a ground work roll having a surface texture with an Ra value from about 0.20 ⁇ m to about 0.50 ⁇ m (e.g., a ground work roll having a surface texture with an Ra value from about 0.30 ⁇ m to about 0.50 ⁇ m); electro-discharge texturing the ground work roll to create an isotropic work roll surface texture having an Ra value from about 0.50 ⁇ m to about 1.0 ⁇ m (e.g., an Ra value from about 0.50 ⁇ m to about 0.8 ⁇ m); polishing the isotropic work roll surface texture to produce a finished work roll with an engineered or particular surface texture having an Ra value from about 0.30 ⁇ m to about 0.70 ⁇ m; inserting the finished work roll into a cold mill; and cold rolling the metal substrate with the finished work roll to apply the isotropic gloss finish on the metal substrate.
• a metal substrate which can be in the form of a metal sheet or plate, that is cold rolled using a surface textured work roll as described above to be further processed into beverage cans, beverage can components (e.g., a can body, can end, or can tab), beverage bottles, other food containers, and/or any other highly-formed metal product with improved ease and efficiency.
• beverage can components e.g., a can body, can end, or can tab
• beverage bottles e.g., can body, can end, or can tab
• beverage bottles e.g., other food containers
• any other highly-formed metal product with improved ease and efficiency.
• one or more improved tribological characteristics of a metal substrate with an isotropic gloss surface imparted by a surface textured work roll as described herein may allow for faster processing and more stable operating conditions because the friction characteristics of the metal sheet or plate may be more consistent between different batches of material and/or along the same strip of metal sheet or plate.
• the improved ability of the surface of the metal substrate to retain lubrication may further reduce friction during processing and reduce the need to apply extra lubrication to the metal substrate.
• improving the quality and consistency of friction for a metal sheet or plate can lead to faster processing with reduced galling, earing, and wrinkling of the metal through subsequent forming operations.
• FIGs. 1A and 1B are a schematic perspective view of a ground work roll surface and a graph depicting the roughness of the ground work roll surface, respectively.
• the work roll which may initially begin with a standard surface finish devoid of marks, scratches, and/or other imperfections that could interfere with the application of an engineered texture surface, may be ground (e.g., using a grit wheel) to achieve a surface finish having an Ra value from about 0.2 ⁇ m to about 0.5 ⁇ m (e.g., an Ra value from about 0.3 ⁇ m to about 0.5 ⁇ m).
• the surface of the work roll may be composed of peaks and valleys and anisotropic.
• FIGs. 1C and 1D are a schematic perspective view of the work roll surface of FIGs. 1A-B after electro-discharge texturing (EDT) and a graph depicting the surface roughness of the EDT work roll surface, respectively.
• EDT electro-discharge texturing
• a texture of the work roll after EDT processing is a relatively uniform, isotropic series of conical peaks with no directional bias.
• using an EDT process to texture the work roll can cause build up on the ground texture of FIG. 1A and produce a texture on the work roll with an Ra value from about 0.5 ⁇ m to about 1.0 ⁇ m with an isotropic distribution that has no directional bias.
• FIGs. 1F and 1G are a schematic perspective view of a work roll surface after polishing to form an engineered surface texture and a graph depicting the surface roughness of the polished work roll surface, respectively.
• polishing the work roll surface can remove sharp peaks of the EDT texture, which results in a surface texture of the work roll having flatter tops and a lower Ra value from about 0.3 ⁇ m to about 0.7 ⁇ m.
• the surface texture depicted in FIGs. 1F and 1G may tend toward a more negative skewness, indicating that the surface texture may be characterized by relatively deeper depressions and flatter peaks.
• FIG. 2 is a micrograph of an engineered surface finish on a metal work roll for rolling metal sheet.
• the engineered surface finish on the metal work roll can refer to a metal work roll having a surface texture with an Ra value from about 0.3 ⁇ m to about 0.7 ⁇ m (e.g., a polished work roll with having a surface texture as described above with respect to FIGs. 1F and 1G).
• an unfinished work roll may be ground to produce a ground work roll with a ground finish or a surface texture having an Ra value from about 0.2 ⁇ m to about 0.5 ⁇ m.
• the unfinished work roll may be ground to produce a ground work roll with a ground finish or a surface texture having an Ra value from about 0.3 ⁇ m to about 0.5 ⁇ m (e.g., an Ra value of about 0.35 ⁇ m or any other suitable Ra value).
• An unfinished work roll may be a smooth work roll with a standard surface finish and no scratch marks, blemishes, indentations, or other surface imperfections that could prevent application of the engineered surface texture.
• the unfinished work roll may be obtained from any suitable commercial source.
• the unfinished work roll may be made from any suitable material, such as, for example steel, ceramics, or any other material suitable for producing a work roll with an engineered surface texture.
• the ground work roll may be electro-discharge texturized to form an EDT work roll.
• the electro-discharge texturing process can build up the ground texture produced at block 302 to a textured finish or an isotropic texture with a larger Ra value from about 0.5 ⁇ m to about 1.0 ⁇ m.
• the electro-discharge texturing process can build up the ground texture produced at block 302 to a textured finish or an isotropic texture with an Ra value from about 0.5 ⁇ m to about 0.8 ⁇ m (e.g., an Ra value of about 0.6 ⁇ m, 0.75 ⁇ m, or any other suitable Ra value).
• the ground work roll may be electro-discharge texturized until a particular or desired roughness or Ra value is achieved.
• the ground work roll can be electro-discharge texturized to form an EDT work roll with an Ra value from about 0.50 ⁇ m to about 1.0 ⁇ m (e.g., an Ra value from about 0.5 ⁇ m to about 0.8 ⁇ m).
• the EDT work roll can have an Rsk value from approximately -1.0 to approximately 1.0.
• the EDT work roll can have a Pc value from about 80/cm to about 140/cm.
• a polarity of an electrode used while electro-discharge texturizing the ground work roll can be alternated while electro-discharge texturizing the ground work roll, which may affect the Ra value of the EDT work roll.
• the EDT work roll is polished to form a polished work roll.
• a sand belt, sandpaper, superfinisher, etc. may be used to polish the EDT work roll to achieve a polished finish.
• Examples of a type of sandpaper that can be used to polish the EDT work roll include, but are not limited to, a 2x15 ⁇ m sandpaper or a 1x9 ⁇ m sandpaper.
• Polishing the EDT work roll in block 306 can also form a polished work roll that can have a lower Ra value than the EDT work roll of block 304.
• the polished work roll can have an Ra value from about 0.30 ⁇ m to about 0.70 ⁇ m (e.g., an Ra value of 0.6 ⁇ m, 0.65 ⁇ m, between approximately 0.6 ⁇ m and 0.65 ⁇ m, or any other suitable Ra value).
• the polished work roll can have an Rsk value from approximately -3.0 to approximately 0.0.
• the polished work roll can have a Pc value from approximately 100/cm to approximately 180/cm.
• a polished work roll with an Ra value from about 0.30 ⁇ m to about 0.70 ⁇ m can be used to apply a gloss finish on a metal substrate.
• FIG. 4 is a flow chart depicting an example of a process for applying a gloss finish on a metal substrate using a polished work roll, according to one example.
• a polished work roll is inserted into a cold mill.
• the polished work roll can be a work roll that has an Ra value from about 0.30 ⁇ m to about 0.70 ⁇ m (e.g., a polished work roll formed in block 306 of FIG. 3).
• a metal substrate can be rolled using the polished work roll.
• the metal substrate can be an aluminum sheet or an aluminum alloy sheet or any suitable substrate.
• the metal substrate is cold rolled using the polished work roll to apply a gloss finish on the metal substrate, which, as described above, can refer to a uniform glossiness of the metal substrate and/or can refer to a metal substrate having a surface that is isotropic with minimal directionality.
• applying the gloss finish to the metal substrate may allow the metal substrate to be suitable for any product that would benefit from a gloss finish lacking strong directionality and having limited surface peaks (e.g., but not limited to, litho applications, can applications, and lacquer applications).
• the gloss finish described herein can be suitable for can ends (e.g., an end of a beverage can), a can body (e.g., a body of a beverage can), a can tab (e.g., a tab of a beverage can), reflectors, painted and laminated products, signage, transportation, anodizing quality, and decorative finishes.
• Applying the gloss finish to a can end or other product may be advantageous as a potential for reducing coating weights since the roughness peak volumes are reduced for a similar average transverse roughness.
• cold rolling the metal substrate using the polished work roll can cause the metal substrate to have a negative skew (e.g., have a valley extending into a surface of the metal substrate), which can increase a volume of lubricant stored in the metal substrate.
• a negative skew e.g., have a valley extending into a surface of the metal substrate
• cold rolling the metal substrate using the polished work roll can cause the metal substrate to have more consistent friction characteristics throughout the metal substrate. In some cases, cold rolling the metal substrate using the polished work roll can cause the metal substrate to have improved formability, which may allow the metal substrate to be less prone to issues resulting from low formability, such as product cracking.

Landscapes

• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Metal Rolling (AREA)
• Reduction Rolling/Reduction Stand/Operation Of Reduction Machine (AREA)
• Grinding Of Cylindrical And Plane Surfaces (AREA)
• Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)
• Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)

Priority Applications (9)

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Publications (1)

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Family Applications (1)

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Cited By (2)

Citations (4)

Family Cites Families (17)

• 2016
  • 2016-11-15 CA CA3007648A patent/CA3007648C/en not_active Expired - Fee Related
  • 2016-11-15 WO PCT/US2016/062087 patent/WO2017099957A1/en active Application Filing
  • 2016-11-15 KR KR1020187019630A patent/KR20180094011A/ko not_active Application Discontinuation
  • 2016-11-15 BR BR112018011559A patent/BR112018011559A2/pt not_active Application Discontinuation
  • 2016-11-15 MX MX2018006958A patent/MX2018006958A/es unknown
  • 2016-11-15 JP JP2018529617A patent/JP6695428B2/ja not_active Expired - Fee Related
  • 2016-11-15 EP EP16805634.9A patent/EP3386657A1/en not_active Withdrawn
  • 2016-11-15 US US15/351,830 patent/US20170165728A1/en not_active Abandoned
  • 2016-11-15 AU AU2016369269A patent/AU2016369269B2/en not_active Ceased
  • 2016-11-15 CN CN201680071942.6A patent/CN108290188A/zh active Pending
  • 2016-11-15 RU RU2018124514A patent/RU2705831C1/ru not_active IP Right Cessation

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