A Sensor-based Process Modeling Approach to Increase the Reliability of Hot Bar Rolling

摘要

In this paper, a minimum sensitivity roll pass design procedure is proposed. The rolled seams are reduced by investigating unconstrained flat passes in a multi-pass square-to-round sequence. The flat pass designs are less constrained and used for large cross-sectional area changes. First, a brief description of roll pass design and the finite element code ROLPAS for modeling of the rolling process are outlined. Then small perturbations to the original nominal design are given and those variables that significantly affect the objective function are selected for design. Finally, the minimum sensitivity analysis is conducted to determine the robust settings for the rolling sequence. A case study using an industrial roll pass design is presented. It demonstrates the efficacy of this approach in analyzing the potential for the formation of rolling surface defect called seam and its elimination. In part two of this process this approach will be integrated with OG Technologies machine vision system to develop a sensor based intelligent system for higher reliability of rolled rods.