The International Journal of Advanced Manufacturing Technology (2018) 96:3321–3330

https://doi.org/10.1007/s00170-018-1691-9

ORIGINAL ARTICLE

An experimental investigation into roughness transfer in skin-pass

rolling of steel strips
Bilal Çolak 1 & Naci Kurgan 2

Received: 26 August 2017 / Accepted: 1 February 2018 / Published online: 4 March 2018
# Springer-Verlag London Ltd., part of Springer Nature 2018

Abstract
The surface of sheet metals should have a certain level of roughness in terms of forming and dyeing quality. Surface roughness is
mainly introduced to the material by rolling with rough rolls, which is called temper rolling. The roughness of a roll is transferred
to the material, depending on the rolling parameters. A 2-high rolling setup equipped with a load-cell measuring the rolling force,
which can roll at different speeds and reduction ratios, was used to observe the change in the amount of roughness transfer.
Surface roughness values of specimens were measured after tests, their average and standard deviation values were calculated,
and 3-D field scanning images were investigated. The results obtained were evaluated in terms of rolling parameters and
roughness transfer. It was concluded that each parameter that increased the rolling force also increased the roughness transfer.
It was seen that rolling force, and thus roughness transfer, was higher in the tests conducted at high speeds and high reduction
ratios with thinner materials. Lubricated roughening tests indicated that the introduction of roughness on material surface
decreased due to lubrication. Moreover, a more homogeneous roughness distribution was obtained in lubricated rolling compared
to dry rolling. It was observed that the roughness at small reduction ratios was obtained within a narrower range.

Keywords Roll roughness . Roughness (transfer) . Temper (skin-pass) rolling . Rolling force . Rolling speed . Lubrication

1 Introduction material surface to have optimal level of roughness and num-

The material surface roughness and number of peaks are sig-
nificant factors affecting the final shaping and dyeing quality
of the material. Surface roughness (Ra) is the arithmetic aver-
age of the centerline distance of the surface profile. High sur-
face roughness provides an advantage in shaping by increas-
ing the lubrication characteristic during the contact of sheet
metal with the mold because it forms oil pockets where the
mold oil can hold on the material surface. However, high
degree of roughness causes the dyed surface to look dull.
High number of peaks (RPc) plays an important role in en-
hancing the bonding ability of the dye; on the other hand, it is
considered as a disadvantage in terms of shaping because it
decreases the volumes that oil can hold on the rough material
surface [1, 2]. Based on these criteria, it is desired for a
* Bilal Çolak
bilalcolak@karabuk.edu.tr; colakbilal@hotmail.com
1
Eskipazar Vocational School, Karabuk University, Karabuk, Turkey
2
Engineering Faculty, Ondokuz Mayis University, Samsun, Turkey
ber of peaks. The roughness value usually changes from 1.0 to
1.5 μm for outer body parts of automobiles and from 1.5 to
2.0 μm for the interior parts [3].
In addition to optimal roughness on the material surface, it
is also necessary that the surface topography has a homoge-
neous distribution. Mazur indicated that rolling parameters do
not depend on only surface roughness of material and rolls;
they also depend on the orientation on the surface topography
of the rolls in the presence of a lubricant. Surface microrelief
should be as uniform as possible in the roll-barrel axis to avoid
additional tensile strains that can cause tears in the direction of
the strip width [4]. Uniform surface microrelief can be obtain-
ed by independently controlling Ra and RPc using the PDT
(Pomini digital texturing) method where roll-barrel surfaces
are randomly and isotropically roughened using a laser at high
frequencies [5].
The material thinned down to a certain thickness by hot
rolling is first pickled and then cold rolled. Both strength
and hardness increases obtained in the strain-hardened mate-
rial during cold rolling make it more brittle. To normalize the
distorted microstructure and obtain desired surface properties,
the material is first annealed at approximately 600 °C and then

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3322
Table 1 Rolling rolls
Surface
roughness
(μm)a
Rough roll 3.4
Very rough roll 8.5
subjected to temper rolling where rough rolls are used and a
1% elongation is introduced. Therefore, roughness, which is
desired on the material surface, is obtained by temper rolling.
There are many variables affecting the roughness transfer
that occurs from the roll surface to the contact region during
rolling. Kimura et al. revealed that roughness transfer in-
creased with increasing elongation, and the roll diameter must
be increased to increase the roughness transfer at the same
elongation values [6]. The SMS group concluded that rough-
ness transfer on both surfaces of the material increased with
increasing strain, and this increase was more apparent in thin-
ner materials [7]. Kijima carried out dry and lubricated exper-
iments using 50 and 250 mm radius rolls and obtained similar
results with SMS group [8]. Furthermore, SMS group empha-
sized that roughness and roll diameter are directly proportion-
al with each other. Kijima, in another study [9], obtained a
contrary result with the SMS group and indicated that there
was an apparent increase in the peak pressure with decreasing
roll diameter, and thus, this increase also increased the rough-
ness transfer. Moreover, he presented the relationship between
rolling force and roughness transfer. He conducted experi-
ments by using 50 and 250 mm radius rolls having 3.1 μm
(rough) and 8 μm (very rough) roughness and found out that
transfer roughness increased with increasing rolling force for
both surface roughness values. It was stated that although a
small increase was observed in the magnitude of the peak
pressure when the rolling force was increased, the roughness
transfer still increased, and this increase was more apparent in
smaller radius (50 mm) rolls [9]. Kijima showed in his study
conducted in 2015 that he achieved the same results [8]. The
results obtained by Wentink are parallel with these results. He
obtained high strip roughness under high rolling forces and
supported this result with microscopic images [10]. On the
other hand, Ma carried out lubricated and dry experiments
using bright rolls at different speeds and different reduction
ratios. According to experimental results, it was indicated that
surface roughness decreased in the materials rolled at lower
Table 2 Material properties
Standard Grade Erdemir Yield strength
grade (N/mm2)
DIN-EN 10130-2006 DC01 ERD6112 236.3
a
Cut-off length is 2.5 mm (based on SEP 1940 standard)
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Int J Adv Manuf Technol (2018) 96:3321–3330
Roll Barrel Texturing Roll material
diameter length (mm) Method
(mm)
75 50 Roughening with Cold work tool
diamond steel (2379)
speed and lower reduction ratios while it increased at higher
speed and higher reduction ratios. That this increase was more
apparent in lubricated rolling conditions was supported by
AFM (atomic force microscope) images [11]. The results ob-
tained by Wu et al. were similar to the studies mentioned
above. They found that the rolling force and roughness trans-
fer increased with increasing reduction ratio. They indicated
that it was not possible to obtain complete (100%) roughness
transfer, and there was almost no roughness transfer at very
small reduction ratios because of elastic deformation [12]. Xia
indicated that the most important factor influencing the rough-
ness of temper-rolled strips is the product of reduction and
tension ratios according to the prediction model for surface
roughness of temper-rolled strips [13]. Kijima, in his study
carried out in 2008, modeled the surface-roughened roll with
circular segments at different ripple heights and pitch.
According to the results of finite element tests, it was empha-
sized that the increasing effect of smaller tool roughness and
larger pitch on the roughness transfer was significant at inter-
mediate pressure values (500 to 750 MPa) [14]. Rui et al., as a
result of FEM simulations done using a two-stand temper mill,
indicated that when the first stand roll roughness was high,
and the second one was low, a narrower roughness range was
obtained on the material surface [15].
2 Experimental procedure
2.1 Test equipment and material
Rolling tests were performed by using a 2-high rolling setup,
with a power of 1.5 kW and two working rolls, which could be
adjusted from 5 to 60 rpm. A 100-t-capacity load cell was
equipped to the setup to correctly measure rolling forces.
Tests were carried out with two double rolls having different
roughness, whose characteristics are shown in Table 1, to
observe how the material surface roughness changes with
Tensile strength Elongation Thickness Surface roughness
(N/mm2) (%) (mm) (μm)a
339.3 36 0.90 1.416
1.83
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Table 3 Rolling parameters

Roll surface roughness Indicator 3.4 8.5
Meaning 3.4 μm (rough roll) 8.5 μm (very rough roll)

Material thickness Indicator 0.9 1.8

Meaning 0.9 mm 1.8 mm
Speed Indicator 10 50
Meaning 10 rpm 50 rpm
Draft Indicator 350 700
Meaning 350 μm 700 μm
Lubricated or dry Indicator D L
Meaning Dry Lubricated

the roll roughness. Test specimens were prepared by cutting to
be 30 mm wide and 300 mm long, and their material proper-
ties are shown in Table 2.
2.2 Rolling experiments
Rolling experiments were performed as dry and lubricated at
different reduction ratios and speeds by using rolls with dif-
ferent roughness and materials with different thickness. The
indication of these variables is shown in Table 3.
According to the presentation in Table 3, the 3.4/0.9/10/
700/L test indicates 3.4 μm roll surface roughness, 0.9 mm
material thickness, 10 rpm speed, 700 μm reduction ratio, and
lubricated condition. Surface roughness measurements of rolls
and test specimens were done by using Mitutoyo SJ-410 sur-
face roughness measurement equipment in Karabuk
University Iron-Steel Institute Metrology Laboratory that has
been accredited by TÜRKAK (Turkish Accreditation
Institution). Measurements were taken three times from the
middle and both ends of the specimen to be parallel and per-
pendicular with the rolling direction. Total 36 measurements
were taken from both surfaces of each specimen, and the stan-
dard deviation of ultimate surface roughness and roughness
distribution was calculated by averaging the arithmetic mean
of these measurements.
Roughness transfer ratio (RTR) passing from the roll to the
material was calculated by using Eq. (1) [8]:
Ra1 −Ra0
RTR½% ¼  100 ð1Þ
Rar −Ra0
where Ra1 is the surface roughness of the material after
rolling, Ra0 is the surface roughness of the material before
rolling, and Rar is the surface roughness of the roll.
In automobile and white goods production, where surface
appearance is important, material surface roughness should be
at a certain level, and the roughness distribution should be
narrow. Thanks to numerous roughness measurements taken
from the material surface, standard deviation indicating rough-
ness distribution homogeneity was calculated in addition to
the roughness transfer ratio, and the results were supported by
3-D field scanning images taken with Nanovea optical profile
measurement device. Scans were done on a 2 × 2 mm field
with 2 μm sensitivity. Values indicated on scanning images by
micrometers are not the average surface roughness (Ra), but
they show the height of the point with respect to the bottom
point determined by the device in its scanning field.
3 Results

3.1 The effect of the rolling speed

In roughening experiments performed at different speeds (10

and 50 rpm) but with constant roll roughness, reduction ratio,
lubrication condition, material thickness, and type, it was seen
that the roughness transfer was higher at high speed (Fig. 1).
Because the material volume crushed per time increases with
increasing speed, the rolling force (Fig. 5) and roughness
transfer increases (Fig. 3).
Ma et al. also obtained similar results. In the experiments
carried out at different speeds (5, 30, and 60 rpm), they found
that at the same reduction ratios, the material roughness, i.e.,
Fig. 1 Experimental roughness transfer ratio as a function of the roll roughness transfer, increased with increasing speed and sup-
speed ported these results with AFM images [11].

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3324
Fig. 2 Influence of lubricant on
roughness transfer
3.2 The effect of the lubrication
In the roughening experiments carried out by keeping the
variables in Table 3 constant, it was observed that the rough-
ness transfer was higher in dry rolling than in lubricated
rolling (Fig. 2). This phenomenon can be explained by that
the rolling force was higher in dry rolling. Hence, the rough-
ness transfer increases with the rolling force. This is because
coefficient of friction is higher in unlubricated rolling, which
causes the rolling force to increase [16]. Indeed, the test results
agree with this explanation. Surface roughness of the material
increases with increasing rolling force (Fig. 3).
This result shows parallelism with the findings of Kijima
[8]. Kijima subjected two different quality materials to rolling
tests by using two rolls with different roughness and two dif-
ferent lubricants (skin-pass lubricant and cold-rolling lubri-
cant) and found out that roughness transfer ratio was higher
in the dry rolling for the same rolling force. Moreover, Dick
et al. [17], who investigated the effect of roll roughness and
viscosity on the rolling force, obtained the same results. They
performed cold rolling experiments by using rolls and three
10 wt.% lubricant emulsions for roughness values up to
Fig. 3 The effect of the rolling
force on roughness transfer. Note:
Tests under 2 kN/mm rolling
force are for 350 μm reduction
ratio; tests above 2 kN/mm rolling
force are for 700 μm reduction
ratio
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Int J Adv Manuf Technol (2018) 96:3321–3330
2.0 μm and indicated that the highest roughness on the mate-
rial surface was obtained in the dry rolling.
3.3 The effect of the rolling force
According to the results of 32 roughening experiments per-
formed by using different variations of the variables in
Table 3, it was seen that roughness transfer increased with
increasing rolling force (Fig. 3). High rolling forces indicate
that sharp peaks on the roughened roll surface are pressed on
the material surface with higher forces. At contact points of
sharp peaks with the material surface, more plastic deforma-
tion occurs under higher forces, and this causes the formation
of deeper craters on the material surface.
It was shown in Fig. 4 that the rolling force at the same
reduction ratio was higher in thinner materials. Thus, higher
roughness transfer is expected in thinner materials under the
same conditions (Fig. 3).
The material passing through two rolls rotating in opposite
directions is plastically deformed above its yield point with the
force applied by the rolls. That the rolling is done at high
speed means that the material volume formed in unit time
Int J Adv Manuf Technol (2018) 96:3321–3330 3325

Fig. 4 The effect of the material

thickness on rolling force

Fig. 5 The effect of the speed on

rolling force

increases, which also increases the rolling force. According to
the experimental results, the relationship between the rolling
speed and rolling force is shown in Fig. 5.
In this study, in the experiments done with very rough rolls,
a higher rolling force was measured compared to the experi-
ments performed using rough rolls (Fig. 6).
The coefficient of friction is directly proportional to chang-
es in the rolling force [16]. Because the coefficient of friction
is higher in dry rolling, the rolling force is higher as well. It
can be seen in Fig. 6 that the results for dry rolling (0.9/10/
350/K, 0.9/10/700/K, 0.9/50/350/K) change in the same way.
The increase in the rolling force is more apparent in dry rolling
due to the increase in the roll roughness.
3.4 Experimental standard deviation
3.4.1 Lubrication effect
For surface roughness of test specimens, the arithmetic
mean of roughness values (Ra) measured from various
points of the material surface was taken. For the dyed
surface appearance quality, mostly, it is not sufficient to

Fig. 6 The effect of the roll

roughness on rolling force

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3326
Fig. 7 Experimental standard
deviation at low speed (10 rpm)
Fig. 8 Experimental standard
deviation at high speed (50 rpm)
achieve only this value. Furthermore, roughness changes
should occur over a narrow range for the overall surface.
The most effective component to impart these characteris-
tics to a flat product is the roll surface roughness. By using
the EDT (electro discharge texturing) method, which is
commonly used in roll surface roughening, a surface
roughness with a ± 4% variation can be obtained in the
rolls having a roughness less than 3.5 μm, while a surface
roughness with a ± 5% variation can be achieved in rolls
having a roughness higher than 3.5 μm [1]. The surface
roughness of rolls roughened by the SBT (shot blast
a) 3D optical field scan image
Fig. 9 Rolling under 3.4/0.9/10/700/L conditions. a 3D optical field scan image. b Roughness distribution (standard deviation 0.18)
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Int J Adv Manuf Technol (2018) 96:3321–3330
texturing) method is much broader, while roughness reten-
tion is more limited.
The more homogeneous the roughness distribution of the
roll is, the more homogeneous the material surface roughness
will be. However, this is not sufficient. Comparing the test
results of speeds at 10 rpm (Fig. 7) and at 50 rpm (Fig. 8), it
is seen that roughness distribution was obtained over a
narrower range when a lubricant was used. This effect was
visualized with 3D surface scans. Figures 9 and 10 show 3D
surface topography images and roughness distribution graphs
for the tests carried out under 3.4/0.9/10/700 conditions.
b) Roughness distribution
(standard deviation: 0.18)
Int J Adv Manuf Technol (2018) 96:3321–3330
a) 3D optical field scan image
Fig. 10 Rolling under 3.4/0.9/10/700/D conditions. a 3D optical field scan image. b Roughness distribution (standard deviation 0.28)
Comparing Fig. 9a for lubricated rolling with Fig. 10a for dry
rolling, it is seen that the surface rolled with a lubricant has a
more homogeneous surface distribution. Figures 9b and 10b
show roughness distribution graphs obtained from a 3D opti-
cal profile measurement device. The more the red curve is
perpendicular (to the axis of roughness), the narrower the
roughness distribution is. It is seen that this curve is more
perpendicular in Fig. 9b. This result reveals that surface
roughness has a more homogeneous distribution in lubricated
rolling. The results manually measured from the material sur-
face by the roughness measurement device are also the same.
The standard deviation was measured as 0.18 in lubricated
rolling while it was 0.28 in dry rolling. It is considered that
this difference was caused by the hydrodynamic effect formed
during the lubricated rolling at the roll/material interface.
3.4.2 Reduction ratio effect
Comparing the test results obtained at 350 μm reduction ratio
with those obtained at 700 μm reduction ratio (Figs. 11 and
12), it is seen that roughness distribution was obtained in a
Fig. 11 Experimental standard
deviation (with rough roll)
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3327
b) Roughness distribution
(standard deviation: 0.28)
narrower range at the smaller reduction ratios. This effect was
visualized by 3D surface scans. Figures 13 and 14 show 3D
surface topography images and roughness distribution graphs
for the tests carried out under 3.4/1.8/10/Y conditions.
Comparing Figs. 13a and 14a, it is observed that the surface
has a more homogeneous roughness distribution at smaller
reduction ratios. Figures 13b and 14b show roughness distri-
bution graphs obtained from a 3D optical profile measurement
device. The more the red curve is perpendicular, the narrower
the roughness distribution is. It is seen that this curve is more
perpendicular in Fig. 13b, which indicates that surface rough-
ness has a more homogeneous distribution at smaller reduc-
tion ratios. The results manually measured from the material
surface by the roughness measurement device are also the
same. The standard deviation was 0.16 at 350 μm reduction
ratio, while it was measured as 0.29 at 700 μm reduction ratio.
When the reduction ratio is low, smaller peaks on the roll
surface do not contribute to roughening because they cannot
contact the material surface. Smaller peaks are significant at
large reduction ratios (increasing the reduction ratio also in-
creases the rolling force), forming craters on the surface that
negatively affect the roughness distribution.
3328
Fig. 12 Experimental standard
deviation (with very rough roll)
4 Discussion
According to the results of this study, the parameter that main-
ly affects the rolling force is the reduction ratio. In Fig. 3, the
tests with a rolling force less than 2 kN/mm correspond to the
tests with 350 μm reduction ratio, while the tests with a rolling
force higher than 2 kN/mm corresponds to the tests with
700 μm reduction ratio. It is seen that the rolling force obtain-
ed with the 700 μm reduction ratio is much higher than that
obtained with 350 μm reduction ratio.
Wentink [10] found out that surface roughness values ob-
tained by using the 1.45 kN/mm rolling force were higher than
those obtained the 0.80 kN/mm rolling force and proved these
results with confocal micrograph images obtained from the
rolled strip surface. Kijima [9], in the experiments performed
using 50 and 250 mm radius rolls having 3.1 and 8 μm rough-
ness, concluded that the roughness transfer ratio increased
with the increased rolling force for both roughness transfer
values. He stated that this increase was more apparent in the
50 mm radius rolls. In another study done by Kijima [8], he
subjected two different quality materials to rolling tests by
using two rolls with different roughness and two different
a) 3D optical field scan image
Fig. 13 Rolling under the 3.4/1.8/10/Y/350 conditions. a 3D optical field scan image. b Roughness distribution (standard deviation 0.16)
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Int J Adv Manuf Technol (2018) 96:3321–3330
lubricants (skin-pass lubricant and cold-rolling lubricant).
According to test results, independently of material quality,
roll roughness, and lubricated-dry condition, roughness trans-
fer increased when the rolling force was increased.
Increasing the reduction ratio increases the rolling force
and thus the roughness transfer (Fig. 3). In fact, Ma et al.
confirmed this relationship [11]. According to the experi-
ments carried out using bright rolls at different speeds and
reduction ratios under lubricated and dry conditions, it was
emphasized that a higher amount of roughness was obtain-
ed on the strip surface at higher speeds and higher reduc-
tion ratios.
In this study, it was found that the rolling speed is directly
proportional to roll force (Fig. 5). On the other hand, Dick
et al. [17] indicated that, with increasing speed, the rolling
force decreased in the rolls having a surface roughness higher
than 1.0 μm, while it did not change in the rolls having a
surface roughness less than 1.0 μm. They explained this result
that, in high rough rolls, the hydrodynamic effect easily forms
under lubricated rolling conditions, which decreases the
rolling force. A decrease in the rolling force also decreases
roughness transfer (Fig. 3).
b) Roughness distribution
(standard deviation: 0.16)
Int J Adv Manuf Technol (2018) 96:3321–3330
a) 3D optical field scan image
Fig. 14 Rolling under the 3.4/1.8/10/Y/700 conditions. a 3D optical field scan image. b Roughness distribution (standard deviation 0.29)
In this study, in the experiments done with very rough rolls,
a higher rolling force was measured compared to the experi-
ments performed using rough rolls (Fig. 6). Dick et al. found
that the rolling force was directly proportional to roll rough-
ness and indicated that this increase was more pronounced at
lower speeds [17]. However, any finding that this effect was
more pronounced at lower speeds could not be found in this
study.
5 Conclusion
This study experimentally investigated the effects of rolling
parameters on roughness transfer. It was found that it was not
necessary to use only roughened rolls to obtain a material with
the desired surface characteristics demanded by the end user.
This is because the same material obtains surface roughness at
different levels using the same roll under different rolling
conditions.
Increasing the reduction ratio, surface roughness of the roll
and the rolling speed increased surface roughness of the ma-
terial. Increasing the reduction ratio increased both the surface
roughness and the roughness distribution range. The highest
standard deviation obtained in the tests using rough rolls was
0.290, while it was 0.646 in the tests using very rough rolls.
When the reduction ratio was increased from 350 to 700 μm,
the standard deviation increased by 65% in the tests using
rough rolls, while it increased by 83% in the tests using very
rough rolls. Therefore, when a high amount of roughness is
desired on the material surface, rolling speed can be increased
or a lubricant can be used rather than increasing the reduction
ratio or using rolls with a high level of roughness.
Accordingly, production will speed up; in addition to that,
roughness will be more homogeneous. On the other hand, it
should be considered that when rolling speed is increased,
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3329
b) Roughness distribution
(standard deviation: 0.29)
rolling force and roll consumption will increase and the pro-
duction can be interrupted due to failures in the rolling system.
The reason for subjecting steel sheets to temper rolling
where a smaller amount of reduction ratio (0.5 to 5%) is in-
troduced, compared to hot and cold rolling, is to obtain a
homogeneous surface roughness on the material surface. It
was found that as a result of experimental studies, temper
rolling—using a thinner material at smaller reduction ra-
tios—increased the homogeneity. Roughness transfer de-
creases by a certain amount because rolling force decreases
at smaller reduction ratios. On the other hand, using a thinner
material at the same reduction ratio increases the rolling force
and the desired level of surface roughness can be obtained.
Acknowledgements This work was supported by Research Fund of the
Karabuk University, project numbers: KBÜ-BAP-15/1-DR-005, KBÜ-
BAP-16/2-DS-014, and KBÜ-BAP-17-DS-397.
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