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An accurate determination of the contact pressure and local sliding in a cold rolling process is an essential step towards the prediction of the roller's life due to wear damage. This investigation utilized finite element analysis to quantify the local contact pressure and local sliding over the rolling bite in a plate cold rolling process. It was the first study to quantify the local sliding distance in a rolling process using the Finite Element Analysis (FEA). The numerical results indicate that the local contact pressure over the rolling bite demonstrates a hill profile, and the peak coincides with the neutral plane. The local sliding distance over the rolling bite demonstrates a double-peak profile with the two peaks appearing at the forward slip and backward slip zones respectively. The amplitude of sliding distance in the backward slip zone is larger than that in the forward slip zone. A stick zone was confirmed between the forward slip and backward slip zones. According to a parametric study, the local contact pressure and sliding distance decrease when the thickness reduction is reduced or the diameter of the roller is decreased. The location of the neutral plane always presents at the rolling exit side of the rolling bite's center. The size of the stick zone enlarges and the sizes of slip zones shrink significantly when the friction coefficient is increased. Finally, a novel concept of wear intensity was defined to examine the wear of the roller based on the local contact pressure and local sliding distance. The results show that a two-peak wear response exists in the backward and forward slip zones. The magnitude of the wear in the backward slip zone is larger than that in the forward slip zone. For a given roller and blank material combination, using a smaller thickness reduction, a smaller diameter roller and a higher friction coefficient condition can reduce the wear of the roller for a single rolling cycle. The current paper develops an understanding of rolling contact responses to the wear of the roller in rolling process. The research method can also be applied to study other rolling or sliding wear problems.

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Parts must be measured to evaluate the manufacturing accuracy in order to check whether their dimension is in expected tolerance. In engineering, parts with free-form surfaces are generally measured by high-precision coordinatemeasuring machines. The measurement accuracy is usually improved by increasing the density of measurement points, which is time-consuming and costly. In this article, a novel sampling method of measurement points for free-form surface inspection is proposed. First, surface inspection is simplified into the inspection of a number of section curves of the surface. Second, B-spline curves constructed with an iterative method are employed to approximate these section curves. Subsequently, data points necessary to construct the B-spline curves are taken as the measurement points. Finally, the proposed method is compared with other two sampling methods. The results indicate that the proposed method greatly reduced the number of measurement points without decreasing the precision of surface modeling.