Adhesive tool wear in the cold roll forming process

► Experimental study of the effect of surface roughness and sliding distance on friction coefficient for the materials interacting during the cold roll forming (CRF) process. ► Empirical study of wear coefficient of AISI D2 tool steel sliding without lubrication against uncoated AISI C1020 hot rolled mild steel. ► Analysis of tool wear mechanisms for CRF of Zincalume coated mild steel. ► Study of debris size distribution obtained in laboratory conditions.