Abstract
Micro-grooves with special structure can reduce the surface friction resistance. Rolling method can be used to form micro-grooves on metal surface efficiently. However, the micro grooves formed by this plastic forming method still had some defects, which had a serious negative impact on the drag reduction and mechanical properties of the micro grooves. Therefore, it is of great significance to optimize the multi pass rolling process to avoid the micro-groove defects. In this paper, a series of analysis on the microstructure, strain and material displacement of micro-grooves were carried out to explain the causes of micro groove defects. It was found that the overall extension of the plate has an adverse effect on the formation of micro-grooves and the hole types of the roller were optimized accordingly. The results of simulation and experiment showed that the optimized roller could produce the designed micro-groove, which perfectly avoided the generation of micro defects.