Research on micro riblets rolling process based on uncertainty analysis

Abstract The research on micro-riblets has always been a hot spot in the field of passive drag reduction. In many manufacturing processes of metal microstructures, roll forming can maintain the integrity of the metal streamlines and obtain residual compressive stress, which can resist the fatigue damage caused by the metal gap. In the process of manufacturing micro-grooves on rolling metal surface, there are inherent uncertainties in various parameters that result in the uncertainty of product formation and that affect the reliability of the micro-groove quality. Therefore, it is of great significance to study the interaction between the forming height (HZ) and the forming pressure (FZ) due to the uncertainty of the parameters. In this research, the micro-riblet structures HZ and FZ during the micro-groove forming process were used as the inspection indicators, and the multi-pass rolling process was optimized with the response surface method (RSM). A simulation method of the micro-groove rolling process with uncertainty was proposed, and a random convergence model based on samples was established. Through the uncertainty analysis, the reduction, workpiece thickness, friction coefficient, rolling speed, and roller diameter were selected as input parameters. The influence of the uncertainty of several process parameters on the molding height and the pressure was studied. The results showed that the roll reduction had a significant effect on the forming height and the pressure in the Z-direction, while the roller diameter only had a significant effect on the rolling force in the Z-direction.