Optimal design of round-oval-round roll pass for the steel bar rolling process
Abstract This study aims to determine the optimal values of the round-oval-round roll pass design parameters. This was applied on two consecutive passes: round-oval and oval-round. That produces a circular cross section from an input of a larger circular cross section through an intermediate oval pa...
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| Format: | Article |
| Language: | English |
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SpringerOpen
2024-12-01
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| Series: | Journal of Engineering and Applied Science |
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| Online Access: | https://doi.org/10.1186/s44147-024-00567-8 |
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| _version_ | 1846101149170532352 |
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| author | Mostafa Rashad Abdelrhman Magdi Mohamed Ezz Ahmed Sayed M. Metwalli |
| author_facet | Mostafa Rashad Abdelrhman Magdi Mohamed Ezz Ahmed Sayed M. Metwalli |
| author_sort | Mostafa Rashad |
| collection | DOAJ |
| description | Abstract This study aims to determine the optimal values of the round-oval-round roll pass design parameters. This was applied on two consecutive passes: round-oval and oval-round. That produces a circular cross section from an input of a larger circular cross section through an intermediate oval pass. The design variables were the oval groove radius and depth. The optimization objectives were to minimize the rolling torque and to maximize the area reduction ratio. A nonlinear, double-stage, three-dimensional finite element model (FEM) is used to calculate the rolling torque and the output shape dimensions. The two-staged FEM yielded realistic and highly accurate results as it imitates the real rolling process, using the actual oval results of the first step directly as input to the second step. The results of the FEM were verified experimentally. A polynomial surrogate meta-model, representing the rolling process, was developed based on the FEM utilizing multivariate regression. Optimal design solutions and design curves were developed. The established optimization procedures achieved a reduction in rolling torque of more than 6% or an increase in the area reduction ratio of up to 11%. The optimal solutions were confirmed using FE and experiment. |
| format | Article |
| id | doaj-art-d053e2afcbe14e53812dacb66ea0b9af |
| institution | Kabale University |
| issn | 1110-1903 2536-9512 |
| language | English |
| publishDate | 2024-12-01 |
| publisher | SpringerOpen |
| record_format | Article |
| series | Journal of Engineering and Applied Science |
| spelling | doaj-art-d053e2afcbe14e53812dacb66ea0b9af2024-12-29T12:33:09ZengSpringerOpenJournal of Engineering and Applied Science1110-19032536-95122024-12-0171112010.1186/s44147-024-00567-8Optimal design of round-oval-round roll pass for the steel bar rolling processMostafa Rashad0Abdelrhman Magdi1Mohamed Ezz Ahmed2Sayed M. Metwalli3Mechanical Design and Production Department, Faculty of Engineering, Cairo UniversityElmarakby Steel CompanyMechanical Design and Production Department, Faculty of Engineering, Cairo UniversityMechanical Design and Production Department, Faculty of Engineering, Cairo UniversityAbstract This study aims to determine the optimal values of the round-oval-round roll pass design parameters. This was applied on two consecutive passes: round-oval and oval-round. That produces a circular cross section from an input of a larger circular cross section through an intermediate oval pass. The design variables were the oval groove radius and depth. The optimization objectives were to minimize the rolling torque and to maximize the area reduction ratio. A nonlinear, double-stage, three-dimensional finite element model (FEM) is used to calculate the rolling torque and the output shape dimensions. The two-staged FEM yielded realistic and highly accurate results as it imitates the real rolling process, using the actual oval results of the first step directly as input to the second step. The results of the FEM were verified experimentally. A polynomial surrogate meta-model, representing the rolling process, was developed based on the FEM utilizing multivariate regression. Optimal design solutions and design curves were developed. The established optimization procedures achieved a reduction in rolling torque of more than 6% or an increase in the area reduction ratio of up to 11%. The optimal solutions were confirmed using FE and experiment.https://doi.org/10.1186/s44147-024-00567-8Finite elementMeta-modelPass designMulti-objective optimizationRound-oval-roundBar rolling |
| spellingShingle | Mostafa Rashad Abdelrhman Magdi Mohamed Ezz Ahmed Sayed M. Metwalli Optimal design of round-oval-round roll pass for the steel bar rolling process Journal of Engineering and Applied Science Finite element Meta-model Pass design Multi-objective optimization Round-oval-round Bar rolling |
| title | Optimal design of round-oval-round roll pass for the steel bar rolling process |
| title_full | Optimal design of round-oval-round roll pass for the steel bar rolling process |
| title_fullStr | Optimal design of round-oval-round roll pass for the steel bar rolling process |
| title_full_unstemmed | Optimal design of round-oval-round roll pass for the steel bar rolling process |
| title_short | Optimal design of round-oval-round roll pass for the steel bar rolling process |
| title_sort | optimal design of round oval round roll pass for the steel bar rolling process |
| topic | Finite element Meta-model Pass design Multi-objective optimization Round-oval-round Bar rolling |
| url | https://doi.org/10.1186/s44147-024-00567-8 |
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