Mathematical Simulation in Optimisation of Roll Pass Progression
The results concern roll pass design for rolling a round bar of a 20mm diameter from a 55mm diameter input. Concerning materials, this roll pass design must cover a wide range of steels, from low-carbon micro-alloyed steels to stainless steels. The roll pass design proposal takes into consideration lower plasticity of certain steels. The comparison was enabled by suggesting two roll pass designs. The classical oval-round roll pass design, where the maximum extension coefficient is set to 1.55 in oval and 1.22 in round grooves. The second roll pass design uses a combination of smooth part of the roll (curves) and round roll passes. Distribution of the extension coefficient in individual passes is similar to that of oval-round series. The paper also compares values of energy-force parameters calculated analytically using the method of finite elements. If we compare the distribution of temperature, stress and size of the grain, it is proved that the oval-round roll pass designs are the best as far as the balanced distribution of the above-mentioned values is concerned. The roll pas design combining smooth part of the roll with a round part does not achieve such balance. However, its advantage lies in far lower requirement for the needed length of the working part of the roll. Five passes are carried out on the smooth part of the roll, which considerably cuts down the required length of the roll body. Therefore it is this variant that will be used in the laboratory of wire rolling created within the project RMSTC.