Asperity Forming Using Printed Tools in Rolling

The new method of asperity forming using plastic film with fine pattern produced by laser printer as a tool was proposed in the previous report. This new method can easily form micro-surface-shape on the metal workpiece. In this research, this method is applied to rolling for forming micro-surface-shape on the large area. The forming length of this method depends on the film length rather than the roll circumference. Therefore, the micro-surface-shape can be formed on large area without repeating by roll circumference. The influence of conditions in rolling on the forming accuracy of micro asperity are investigated. The workpiece material is pure aluminum sheet A1050-O. The soft material tools are laser-printed PET (polyethylene terephthalate) film. The experimental result showed that the pattern of asperities is expanded in the rolling direction. When the large-diameter roll (d = 80 mm) is used, uniform asperity can be formed with uniform workpiece thickness. However, when the small diameter roll (d = 40 mm) is used, the workpiece has the thickness distribution in the width direction.