Circular Rolling Mill Modeling for Tool Force and Displacement
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Solution Overview
Problem
Current modeling techniques for circular rolling methods are inadequate as they fail to accurately account for the simultaneous movements of tools and the resulting changes in the bar section, leading to inaccurate predictions and the need for physical prototypes to validate casting sequences.
Innovation Solution
A method for modeling the behavior of a circular rolling mill that takes into account the interactions and movements of all movable tools, using a control formula to link setpoints to tool movements, and incorporating mechanical models to account for force limitations and mandrel stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If finite element computations are used to model circular rolling without adaptative tool operation, then modeling complexity is reduced, but manufacturing precision and reliability deteriorate due to inaccurate predictions of tool behavior and forces
Solution Approach 1:
The patent pre-calculates and stores force thresholds for tapered rollers and stiffness values for mandrels in lookup tables before the rolling process. During modeling, these pre-computed mechanical parameters are directly retrieved and applied, eliminating the need for complex real-time mechanical calculations while ensuring accurate prediction of tool behavior and forces
Solution Approach 2:
The patent introduces a control formula as an intermediary layer between the setpoint (desired outcome) and the actual tool movements. This control formula translates the setpoint into specific tool displacement commands, enabling accurate simulation of adaptative tool operation without requiring complex mechanical models of the entire rolling system
2Adaptability or versatility
If existing servo-assistance models integrating Simufact codes are used, then adaptative tool operation is accounted for, but manufacturing precision deteriorates because mechanical aspects of the rolling mill are not considered
Solution Approach 1:
The patent merges two separate modeling approaches: the servo-assistance control model (which handles adaptative tool operation) and the finite element mechanical model (which handles structural behavior). By combining these models and exchanging data between them (control formulas with mechanical parameters), the solution achieves both adaptative tool operation and accurate mechanical predictions
Solution Approach 2:
The patent divides the modeling system into distinct functional segments: a control formula segment that manages tool movements based on setpoints, and a finite element segment that calculates mechanical forces and deformations. Each segment handles specific aspects independently, then their results are integrated to provide comprehensive and accurate predictions
3Measurement precision
If physical parts are produced to validate casting sequences and retrieve tool displacement data, then measurement precision improves, but loss of time and productivity deteriorate significantly
Solution Approach 1:
The patent creates a virtual copy (digital model) of the circular rolling mill that replicates the behavior of the physical system. This digital twin allows for virtual validation of casting sequences, retrieving tool displacement data and force information through simulation rather than physical experimentation, thereby eliminating time-consuming and costly prototype production while maintaining data accuracy
Data Source
AI summary
The invention relates to a method for modelling the behaviour of a circular rolling mill (1) intended for rolling a cylindrical component on the basis of a setpoint, the circular rolling mill comprising at least one tapered roller (3) configured to effect a translational movement in a first direction (Y), and a mandrel (2), configured to effect a translational movement in a second direction (X), the setpoint comprising a setpoint for the rate of increase of an outside diameter of said cylindrical component as a function of said external diameter, and a setpoint for the height of the cylindrical component in the first direction as a function of a thickness of the cylindrical component in the second direction.