Multi-objective optimization of parametric design for profile ring rolling process based on residual stress control

Liang, Nan; Liu, Dong; Yang, Haisheng; Yu, Yanlong; Wang, Jianguo

doi:10.1007/s00170-021-08096-x

Cited by 17 publications

(8 citation statements)

References 17 publications

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“…Temperature Rolling Process Material Numerical Method [22] 15 Hot rolling Cross-wedge rolling AISI 1045 FEM [23] 14 Hot rolling Ring rolling AA2219 FEM [24] 13 Hot rolling Ring rolling TC4 Ti alloy FEM [25] 9 1 shows that in twenty-five of the thirty publications selected, different hot rolling processes have been studied, which represents more than 80% of the articles included in the table. Hot rolling is a metal manufacturing process extensively used to obtain finished and semi-finished products.…”

Section: Refs Year Citationsmentioning

confidence: 99%

“…In terms of the materials studied, aluminum alloys and steels are the most tested materials, being present in eleven and ten of the articles included in Table 1, respectively. In other studies, simulations of rolling processes have been carried out for titanium [24,34,35,43], copper [32,38], magnesium [28,39,45], and molybdenum [40] alloys and nickel-based superalloys [25,42]. In four papers, clad plates consisting of two different materials [32,35,45,48] have been studied.…”

Section: Refs Year Citationsmentioning

confidence: 99%

See 1 more Smart Citation

Numerical Simulation as a Tool for the Study, Development, and Optimization of Rolling Processes: A Review

Ojeda-López,

Botana-Galvín,

González-Rovira

et al. 2024

Metals

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Rolling is one of the most important processes in the metallurgical industry due to its versatility. Despite its inherent advantages, design and manufacturing by rolling still rely on trial-and-error-based optimizations, which reduces its efficiency. To minimize the cost and time spent on the development of new rolling schedules, various analytical and numerical methods have been used in recent years. Among other alternatives, simulations based on the finite element method (FEM) are the most widely used. This allows for the analysis of the feasibility of new rolling schedules considering metal alloys with different characteristics, process conditions, or the creation of new operations, as well as the optimization of existing ones. This paper presents a literature review including the latest developments in the field of numerical simulation of rolling processes, which have been classified according to the type of rolling into the following categories: flat rolling, shape rolling, ring rolling, cross-wedge rolling, skew rolling, and tube piercing.

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Section: Refs Year Citationsmentioning

confidence: 99%

Section: Refs Year Citationsmentioning

confidence: 99%

Numerical Simulation as a Tool for the Study, Development, and Optimization of Rolling Processes: A Review

Ojeda-López,

Botana-Galvín,

González-Rovira

et al. 2024

Metals

View full text Add to dashboard Cite

show abstract

“…Cleaver et al [24] revealed the curvature development in ring rolling by means of FEM simulation and experiment. Lv et al [25] investigated the effect of different rolling processes on the residual stresses in ring parts by FEM.…”

Section: Introductionmentioning

confidence: 99%

Feed Curves for Controlling Ring Rolling Stability in Large-Scale Flat Ring Rolling Process

Xie

Ouyang

et al. 2023

Materials

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Due to the large wall thickness difference and serious instability in the large-scale ring rolling process, most studies on the feed curve are not suitable for a large-scale ring. The production cost of the large-scale ring is high, and if plastic instability occurs, it will cause a great waste of resources. Therefore, in this study, a staged feed strategy based on the evolution of ring instability is proposed with the objective of controlling the rolling stability of a large-scale ring. Firstly, based on the law of rolling instability evolution, the rolling stage during the rolling process is divided. Secondly, the coordination of all rolling stages is proposed as a factor to design the feed curve. The feed scheme is determined using the central composite design (CCD) method, and then the established mathematical model is applied to obtain the radial feed curves of a large-scale flat ring with a 5 m diameter for different schemes. Next, the designed feed curve was submitted to finite element method (FEM) simulation. According to the FE simulation results, a rolling map for controlling roundness error, eccentricity and vibration is established. Finally, the feed curve in the stable region is input to the FE simulation and the production trial to obtain the results of roundness error, eccentricity and vibration. A comparison of the simulation and production trial results shows that they are in good agreement, which proves the reliability of the feed curve designed based on the stable rolling region in the roll map. Moreover, the machining amount for both the simulation and production trial is below the maximum machined value.

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“…The application aspect of multiobjective optimization methods is used in the fields of engineering, economics, and mathematics. It has high-efficiency global analysis capabilities for complex and nonlinear problems, is suitable for dealing with complex problems, and can effectively optimize process parameters [ 26 , 27 , 28 ]. Saedon et al [ 29 ] adopted the Taguchi method as the experimental design method to study the effect of surface roughness, machining speed, and metal removal rate on wire electrical discharge machining (WEDM), and simplified the complex analysis process through the grey relation manner.…”

Section: Introductionmentioning

confidence: 99%

A Comparison and Analysis of Three Methods of Aluminum Crown Forgings in Processing Optimization

Chen

Shih

et al. 2022

Materials

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In this study, three parameter optimization methods and two designs of experiments (DOE) were used for the optimization of three major design parameters ((bill diameter (D), billet length (L), and barrier wall design (BWD)) in crown forging to improve the formability of aluminum workpiece for shock absorbers. The first optimization method is the response surface method (RSM) combined with Box–Behnken’s experimental design to establish fifteen (15) sets of parameter combinations for research. The second one is the main effects plot method (MEP). The third one is the multiobjective optimization method combined with Taguchi’s experimental design method, which designed nine (9) parameter combinations and conducted research and analysis through grey relational analysis (GRA). Initially, a new type of forging die and billet in the controlled deformation zone (CDZ) was established by CAD (computer-aided design) modeling and the finite element method (FEM) for model simulation. Then, this investigation showed that the optimal parameter conditions obtained by these three optimization approaches (RSM, MEP, and multiobjective optimization) are consistent, with the same results. The best optimization parameters are the dimension of the billet ((D: 40 mm, the length of the billet (L): 205 mm, and the design of the barrier wall (BWD): 22 mm)). The results indicate that the optimization methods used in this research all have a high degree of accuracy. According to the research results of grey relational analysis (GRA), the size of the barrier wall design (BWD) in the controllable deformation zone (CDZ) has the greatest influence on the improvement of the preforming die, indicating that it is an important factor to increase the filling rate of aluminum crown forgings. At the end, the optimized parameters are verified by FEM simulation analysis and actual production validation as well as grain streamline distribution, processing map, and microstructure analysis on crown forgings. The novelty of this work is that it provides a novel preforming die through the mutual verification of different optimization methods to solve a typical problem such as material underfill.

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Multi-objective optimization of parametric design for profile ring rolling process based on residual stress control

Cited by 17 publications

References 17 publications

Numerical Simulation as a Tool for the Study, Development, and Optimization of Rolling Processes: A Review

Numerical Simulation as a Tool for the Study, Development, and Optimization of Rolling Processes: A Review

Feed Curves for Controlling Ring Rolling Stability in Large-Scale Flat Ring Rolling Process

A Comparison and Analysis of Three Methods of Aluminum Crown Forgings in Processing Optimization

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