Revolute - Rolling Enhancement via Optimization of chosen Lubricants and digital Texturing

Initial situation:

In cold rolling, the lubricants used and the surface structure of the work rolls significantly influence friction conditions, energy consumption, roll wear and strip surface quality. Until now, lubrication and roll texturing have largely been optimised separately, leaving potential synergies unexploited. At the same time, requirements for energy efficiency, sustainability and product quality are continuously increasing.

Project targets:

The European research project REVOLUTE aims to optimise the cold rolling process through the targeted combination of sustainable industrial lubricants and laser-textured work rolls. The main objectives are to reduce friction, rolling forces, energy consumption and roll wear while improving surface quality. The developed solutions will be investigated and validated through laboratory, pilot-scale and industrial rolling trials.

Innovative approaches:

A key innovative approach is the development of suitable sustainable lubricants in combination with digital laser texturing technology (PDT™), which enables the precise adjustment of defined surface structures. The lubricant/texture combinations will be investigated regarding their tribological behaviour. At BFI, long-term trials will be conducted using a 3-roll wear test stand. In addition, a predictive model will be developed to describe the transfer of surface roughness from the work rolls to the steel strip and to support the optimisation of roll texturing parameters.

Benefits for the industry:

The project results are expected to enable a more energy-efficient, resource-efficient and cost-effective cold rolling process. Anticipated benefits include lower production costs, extended roll service life, improved strip surface quality and reduced CO₂ emissions. Industrial validation will provide the basis for the future implementation of the developed technologies in existing cold rolling mills.

About the project:

Duration: 01.10.2026 – 31.03.2030

This project has received funding from the Research Fund for Coal and Steel (RFCS). Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union. Neither the European Union nor the granting authority can be held responsible for them.

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