Towards Energy Efficient Shape Rolling:Roll Pass Optimal Design and Case Studies
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摘要
Shape rolling is widely employed in the production of long workpieces with appropriate cross-section profiles for other industrial applications. In the development of shape rolling systems, roll pass design(RPD) plays an essential role on the quality control of products, service life of rolls, productivity of rolling systems, as well as energy consumption of rolling operations. This study attempts to establish a generic strategy based on hybrid modeling and an improved genetic algorithm, to support the optimizations of RPD and shape rolling operations at a systematic perspective.Objectives include improving the quality and e ciency of RPD, reducing energy consumption of shape rolling, as well as releasing the demands on costly trails and expert knowledge in RPD. Hybrid modeling based on cross-disciplinary knowledge is developed to overcome the limitations of isolated single-disciplinary models. And conventional genetic algorithm is improved for the implementation of optimal design. Targeting to integrate empirical data and published reliable solutions into optimizations, a parameters estimation method is proposed to transfer the initially misaligned models into a uniform pattern. A tool based on the Matlab platform is developed to demonstrate the optimal design operations, with case studies involved to validate the proposed methodology.
Shape rolling is widely employed in the production of long workpieces with appropriate cross-section profiles for other industrial applications. In the development of shape rolling systems, roll pass design(RPD) plays an essential role on the quality control of products, service life of rolls, productivity of rolling systems, as well as energy consumption of rolling operations. This study attempts to establish a generic strategy based on hybrid modeling and an improved genetic algorithm, to support the optimizations of RPD and shape rolling operations at a systematic perspective.Objectives include improving the quality and e ciency of RPD, reducing energy consumption of shape rolling, as well as releasing the demands on costly trails and expert knowledge in RPD. Hybrid modeling based on cross-disciplinary knowledge is developed to overcome the limitations of isolated single-disciplinary models. And conventional genetic algorithm is improved for the implementation of optimal design. Targeting to integrate empirical data and published reliable solutions into optimizations, a parameters estimation method is proposed to transfer the initially misaligned models into a uniform pattern. A tool based on the Matlab platform is developed to demonstrate the optimal design operations, with case studies involved to validate the proposed methodology.
Shape rolling is widely employed in the production of long workpieces with appropriate cross-section profiles for other industrial applications. In the development of shape rolling systems, roll pass design(RPD) plays an essential role on the quality control of products, service life of rolls, productivity of rolling systems, as well as energy consumption of rolling operations. This study attempts to establish a generic strategy based on hybrid modeling and an improved genetic algorithm, to support the optimizations of RPD and shape rolling operations at a systematic perspective.Objectives include improving the quality and e ciency of RPD, reducing energy consumption of shape rolling, as well as releasing the demands on costly trails and expert knowledge in RPD. Hybrid modeling based on cross-disciplinary knowledge is developed to overcome the limitations of isolated single-disciplinary models. And conventional genetic algorithm is improved for the implementation of optimal design. Targeting to integrate empirical data and published reliable solutions into optimizations, a parameters estimation method is proposed to transfer the initially misaligned models into a uniform pattern. A tool based on the Matlab platform is developed to demonstrate the optimal design operations, with case studies involved to validate the proposed methodology.
引文
[1]T Traub,X Chen,P Groche.Experimental and numerical investigation of the bending zone in roll forming.International Journal of Mechanical Sciences,2017,131-132:956-970.
[2]S J Lee,S M Kim,D C Ko,et al.Design of roll profile in shape rolling of an irregular angle bar by the modified butterfly method.International Journal of Precision Engineering and Manufacturing,2013,14:93-102.
[3]B Huang.Parameterized hybrid modelling for optimal roll pass design in hot rolling of light-round profiles.Adelaide:University of South Australia,2013.
[4]L X Tang,J Y Liu,A Y Rong,et al.A review of planning and scheduling systems and methods for integrated steel production.European Journal of Operational Research,2001,133:1-20.
[5]R E Beynon.Roll design and mill layout.Pittsburgh:Association of Iron and Steel Engineers,1956.
[6]C Xu,Q S Wang,C Zhang.Roll pass design for shape rolling.Beijing:Chemical Industry Press,2009.(in Chinese)
[7]B Huang,K Xing,K Abhary,et al.Development of energy-saving optimization for the oval-edging oval roll pass design using genetic algorithm.The International Journal of Advanced Manufacturing Technology,2012,61:423-429.
[8]S A Hsiang,S L Lin.Modelling and optimization of caliber rolling process.Journal of Manufacturing Science and Engineering,2007,129:77-83.
[9]F Lambiase.Optimization of shape rolling sequences by integrated artificial intelligent technique.The International Journal of Advanced Manufacturing Technology,2013,68:443-452.
[10]V Oduguwa,R Roy.A review of rolling system design optimization.International Journal of Machine Tools&Manufacture,2006,46:912-928.
[11]A Said,J G Lenard,A R Ragab,et al.The temperature,roll force and roll torque during hot bar rolling.Journal of Materials Processing Technology,1999,88:147-153.
[12]S H Zhang,D W Zhao,C R Gao.The calculation of roll torque and roll separating force for broadside rolling by stream function method.International Journal of Mechanical Sciences,2012,57:74-78.
[13]K Abrinia,A Fazlirad.Investigation of single pass shape rolling using an upper bound method.Journal of Materials Engineering and Performance,2010,19:541-552.
[14]L W Zhang,C X Yue,S Y Yuan,et al.Finite element simulation of rod and wire continuous rolling.Journal of Shanghai Jiaotong University(Science),2011,16:195-198.
[15]R C Spoorenberg,H H Snijder,J C D Hoenderkamp.Finite element simulations of residual stresses in roller bent wide flange sections.Journal of Constructional Steel Research,2011,67:39-50.
[16]U U Hanoglu,B?arler.Multi-pass hot-rolling simulation using a meshless method.Computers&Structures,2018,194:1-14.
[17]E N Chumachenko,S A AksenovI,V Logashina.Mathematical modelling and energy conservation for rolling in passes.Metallurgist,2010,54:498-504.
[18]F Lambiase,A Langella.Automated procedure for roll pass design.Journa of Materials Engineering and Performance,2009,18:263-272.
[19]M Bagheripoor,H Bisadi.Application of artificial neural networks for the prediction of roll force and roll torque in hot strip rolling process.Applied Mathematical Modelling,2013,37:4593-4607.
[20]S H Kim,Y T Im.A knowledge-based expert system for roll pass and profile design for shape rolling of round and square bars.Journal of Materials Processing Technology,1999,89-90:145-151.
[21]H C Kwon,Y T Im.Interactive computer-aided-design system for roll pass and profile design in bar rolling.Journal of Materials Processing Technology,2002,123:399-405.
[22]M Poursina,N T Dehkordi,A Fattahi,et al.Application of genetic algorithms to optimization of rolling schedules based on damage mechanics.Simulation Modelling Practice and Theory,2012,22:61-73
[23]B Huang,K Xing,K Abhary,et al.Optimization of oval-round pass design using genetic algorithm.Journal of Robotics and Computer Integrated Manufacturing,2012,28:493-499.
[24]A Abraham,L Jain.Evolutionary multiobjective optimization:Theoretical advances and applications.London:Springer,2005.
[25]L H Randy,E H Sue.Practical genetic algorithms.2nd ed.Hoboken:John Wiley and Sons,2004.
[26]B Huang,K Xing,K Huang,et al.Development of a geometric modelling strategy for roll pass optimal design.Robotics and Computer-Integrated Manufacturing,2014,30:622-628.
[27]J Zhu,Z C Huang,X L Peng.Curve similarity judgment based on the discrete fréchet distance.Journal of Wuhan University(Nat.Sci.Ed),2009,55:227-232.
[28]V N Djadechko.Roll pass design(Summary of lectures).Training Programme in The Iron and Steel Industry for The UN Fellowship Holders at Zaporozhstal Steel Works.(accessed on 8/09/2018).
[29]M Gen,R Cheng.Genetic algorithms and engineering design.New York:Wiley,2000.
[30]N Zhang.The multi-objective optimal pass design based on GA.Qinhuangdao:Yanshan University,2006.(in Chinese)
[2]S J Lee,S M Kim,D C Ko,et al.Design of roll profile in shape rolling of an irregular angle bar by the modified butterfly method.International Journal of Precision Engineering and Manufacturing,2013,14:93-102.
[3]B Huang.Parameterized hybrid modelling for optimal roll pass design in hot rolling of light-round profiles.Adelaide:University of South Australia,2013.
[4]L X Tang,J Y Liu,A Y Rong,et al.A review of planning and scheduling systems and methods for integrated steel production.European Journal of Operational Research,2001,133:1-20.
[5]R E Beynon.Roll design and mill layout.Pittsburgh:Association of Iron and Steel Engineers,1956.
[6]C Xu,Q S Wang,C Zhang.Roll pass design for shape rolling.Beijing:Chemical Industry Press,2009.(in Chinese)
[7]B Huang,K Xing,K Abhary,et al.Development of energy-saving optimization for the oval-edging oval roll pass design using genetic algorithm.The International Journal of Advanced Manufacturing Technology,2012,61:423-429.
[8]S A Hsiang,S L Lin.Modelling and optimization of caliber rolling process.Journal of Manufacturing Science and Engineering,2007,129:77-83.
[9]F Lambiase.Optimization of shape rolling sequences by integrated artificial intelligent technique.The International Journal of Advanced Manufacturing Technology,2013,68:443-452.
[10]V Oduguwa,R Roy.A review of rolling system design optimization.International Journal of Machine Tools&Manufacture,2006,46:912-928.
[11]A Said,J G Lenard,A R Ragab,et al.The temperature,roll force and roll torque during hot bar rolling.Journal of Materials Processing Technology,1999,88:147-153.
[12]S H Zhang,D W Zhao,C R Gao.The calculation of roll torque and roll separating force for broadside rolling by stream function method.International Journal of Mechanical Sciences,2012,57:74-78.
[13]K Abrinia,A Fazlirad.Investigation of single pass shape rolling using an upper bound method.Journal of Materials Engineering and Performance,2010,19:541-552.
[14]L W Zhang,C X Yue,S Y Yuan,et al.Finite element simulation of rod and wire continuous rolling.Journal of Shanghai Jiaotong University(Science),2011,16:195-198.
[15]R C Spoorenberg,H H Snijder,J C D Hoenderkamp.Finite element simulations of residual stresses in roller bent wide flange sections.Journal of Constructional Steel Research,2011,67:39-50.
[16]U U Hanoglu,B?arler.Multi-pass hot-rolling simulation using a meshless method.Computers&Structures,2018,194:1-14.
[17]E N Chumachenko,S A AksenovI,V Logashina.Mathematical modelling and energy conservation for rolling in passes.Metallurgist,2010,54:498-504.
[18]F Lambiase,A Langella.Automated procedure for roll pass design.Journa of Materials Engineering and Performance,2009,18:263-272.
[19]M Bagheripoor,H Bisadi.Application of artificial neural networks for the prediction of roll force and roll torque in hot strip rolling process.Applied Mathematical Modelling,2013,37:4593-4607.
[20]S H Kim,Y T Im.A knowledge-based expert system for roll pass and profile design for shape rolling of round and square bars.Journal of Materials Processing Technology,1999,89-90:145-151.
[21]H C Kwon,Y T Im.Interactive computer-aided-design system for roll pass and profile design in bar rolling.Journal of Materials Processing Technology,2002,123:399-405.
[22]M Poursina,N T Dehkordi,A Fattahi,et al.Application of genetic algorithms to optimization of rolling schedules based on damage mechanics.Simulation Modelling Practice and Theory,2012,22:61-73
[23]B Huang,K Xing,K Abhary,et al.Optimization of oval-round pass design using genetic algorithm.Journal of Robotics and Computer Integrated Manufacturing,2012,28:493-499.
[24]A Abraham,L Jain.Evolutionary multiobjective optimization:Theoretical advances and applications.London:Springer,2005.
[25]L H Randy,E H Sue.Practical genetic algorithms.2nd ed.Hoboken:John Wiley and Sons,2004.
[26]B Huang,K Xing,K Huang,et al.Development of a geometric modelling strategy for roll pass optimal design.Robotics and Computer-Integrated Manufacturing,2014,30:622-628.
[27]J Zhu,Z C Huang,X L Peng.Curve similarity judgment based on the discrete fréchet distance.Journal of Wuhan University(Nat.Sci.Ed),2009,55:227-232.
[28]V N Djadechko.Roll pass design(Summary of lectures).Training Programme in The Iron and Steel Industry for The UN Fellowship Holders at Zaporozhstal Steel Works.(accessed on 8/09/2018).
[29]M Gen,R Cheng.Genetic algorithms and engineering design.New York:Wiley,2000.
[30]N Zhang.The multi-objective optimal pass design based on GA.Qinhuangdao:Yanshan University,2006.(in Chinese)