Integrated Multiscale Simulation Framework for Cold Rolling With Oil-Free Lubricants: Development and Preliminary Validation

This work presents the preliminary prototype of Mathematical Model of Cold Rolling (MMCR) developed in the project “Transfer of aqueous oil-free lubricants into steel cold rolling practice”. MMCR integrates 1D, 2D, and micro-scale models to estimate mechanical, thermal, and tribological behavior of cold rolling processes using Oil-Free Lubricants. Key components include a Cold Rolling 1D Simulator, validated against pilot mill tests, and a micro-to-macro model bridging asperity-level simulations to continuum-scale predictions. The system demonstrates strong predictive capabilities, supports lubricant design, and is scalable to multi-stand industrial mills. This integrated approach enables efficient simulation of complex rolling conditions reducing reliance on empirical calibration