Integration of automated roll pass design and simulation for the development of shape rolling technology

Abstract. The shape rolling technology is a productive manufacturing process. Meanwhile, its efficiency is highly dependent on a proper roll pass design and accurate adjusting of a rolling mill, which is especially critical for new products and complicated profile shapes. Traditionally, the roll pass design methods have been developed relying on extensive experience and knowledge accumulation, resulting in empirical rules expressed by analytical formulae. Nowadays, some design methods are converted into computer programs to speed up calculations. Nonetheless, the approach based on empirical rules has limitations, especially when implemented to develop the rolling technology for new materials and complex shape profiles. The effectiveness of the roll pass design can be significantly enhanced with the help of finite element (FE) simulation of the material deformation that happens in the stands of the rolling mill. The material flow prediction provided by FE simulation is more accurate than empiric formulae, leading to more accurate load, torque, and energy estimations. The presented paper is focused on the integration of the FE simulation of the rolling process with the roll pass design to make it effective and automated for a wide variety of profile shapes.