Towards Energy Efficient Shape Rolling: Roll Pass Optimal Design and Case Studies

Abstract

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 efficiency 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.

Towards Sustainability of Manufacturing Processes by Multiobjective Optimization: A Case Study on a Submerged Arc Welding Process

“…Energy consumption [12]- [21] Carbon emission [16]- [18], [20]- [22] Material and/or tool waste [19], [21], [23] Economic Cost [17], [21], [22] Productivity [12]- [14], [20]- [22], [24] Quality [12]- [15], [19], [21], [23]- [26] Social Health and safety [18] Labor and workforce training [21] On the contrary, the a posteriori approach, firstly, brings the set of non-dominated solutions (which are optimal in the wide sense that no other solution in the considered search space, can improve one of the objectives without worsening, at least, another one), which is known as the Pareto front and, after that, allows choosing the most convenient alternative from these solutions [27]. Pareto-based techniques have become the most suitable choice for solving multi-objective optimization problems [28] and has been widely applied for practical manufacturing cases [29].…”