Analysis of friction and surface roughness effects on edge crack evolution of thin strip during cold rolling

Experimental investigation and mechanical analysis have been carried out to study the edge crack formation during cold strip rolling using Atomic Force Microscopy (AFM) and Scanning Electron Microscopy (SEM). The effects of friction and surface roughness on edge crack initiation and growth rate have been discussed. Friction leads to an increase in fracture loads and decreasing the friction coefficient is effective in preventing the microcracks. Surface roughness variation along the strip width contributes to stress distribution and inhibits crack nucleation. The findings reveal that the behaviour of crack evolution is influenced by fracture surface roughness as well as rolling friction.