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a
Agency for Defense De6elopment, Jinhae, South Korea
Department of Mechanical Engineering, Computer Aided Materials Processing Laboratory, ME3227 Korea Ad6anced Institute of Science &
Technology, 373 -1, Kusong-dong, Yusong-gu, Taejon 305 -701, South Korea
Abstract
In shape rolling, the determination of roll pass and profile design is of importance. In the present investigation, a
knowledge-based expert system is developed for the design of roll pass and profile sequences for the shape rolling of round and
square bars. For development of the program, C + + language and an object oriented programming technique were utilized in
consideration of the flexibility and expandability of the program. A backward chaining algorithm was employed for the inference
engine to determine the manufacturing sequences in reverse order based on design rules extracted from the literature. For
optimization of the process sequence design, the number of roll passes was minimized by comparing the error between the inferred
roll passes and the initial error provided as input. In the currently developed expert system, five geometries such as box, square,
diamond, oval and round were introduced as a basic geometry to describe the intermediate roll geometries. In addition, the roll
separating force, area reduction and change of length at each stage of shape rolling were determined and displayed on the monitor
of a personal computer. The system was applied for the shape rolling of round and square bars. The process sequences determined
were proven to be reasonable compared to those available at practice. 1999 Elsevier Science S.A. All rights reserved.
Keywords: Shape rolling; Roll pass design; Roll profile design; Expert system; Backward chaining; Object oriented programming
1. Introduction
Shape rolling is generally used for manufacturing
structural or mechanical components with uniform
cross-section in mass production. Due to the recent
development of continuous casting, it can be applied
for producing complex geometries with non-ferrous
materials such as copper and aluminum alloys. Structural H-beams and rails for the railroad are typical
products manufactured by shape rolling.
Process sequence design of shape rolling consists of
roll pass design and profile design, which will enable a
simple billet to be transformed into a final complex
shape. In general, sequence design relies on empirical
rules or the know-how of design engineers, requiring
costly effort at the development stage. Therefore, many
studies have been carried out, experimentally and numerically, on shape rolling for better design.
* Corresponding author. Tel.: +82-42-8693227; fax: + 82-428693210.
E-mail address: ytim@convex.kaist.ac.kr (Y.-T. Im)
0924-0136/99/$ - see front matter 1999 Elsevier Science S.A. All rights reserved.
PII: S 0 9 2 4 - 0 1 3 6 ( 9 9 ) 0 0 0 5 5 - 2
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S.-H. Kim, Y.-T. Im / Journal of Materials Processing Technology 8990 (1999) 145151
Fig. 1. Various roll pass sequences for the rolling of a round bar from
a rectangular billet.
S.-H. Kim, Y.-T. Im / Journal of Materials Processing Technology 8990 (1999) 145151
147
The developed system is also divided into six modules as, shown in Fig. 4.
The input module is for inputting the initial billet
geometry, the final geometry of the product, the initial
temperature and the type of the material. The module
for pass selection and determination of the elongation
coefficient automatically carries out the process design
utilizing PSDB and ECDB in the developed system.
The module for the modification of the elongation
coefficient checks and transforms the automatically
suggested elongation coefficient, depending on the necessary condition for each elongation coefficient compared to the total elongation coefficient. The module
for pass data calculation determines the seven geometry
factors, B, H, R, R2, s, a and F for each pass, the
module for engineering data calculation being included
for providing design engineers with necessary engineering data. The output module is for generating the
necessary outputs of the designed drawings of the process and graphics of the engineering data calculated.
The structures of the five data classes used in the
developed program are introduced in the following.
Here, member data and member functions are parameters representing each item of information and functions for controlling the member data of the
corresponding class, respectively. In addition, friend
function represents a joint function that can be used at
the various classes for controlling the corresponding
information outside of the class.
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S.-H. Kim, Y.-T. Im / Journal of Materials Processing Technology 8990 (1999) 145151
2.2.1. IS class
This consists of the data representing the initial billet geometry (type, B, area, Length), member function
(Select Initial Shape(), Get Size()) and friend function (Area()) determining the initial cross-sectional
area required. Member data type is the parameter
representing the initial billet geometry, which can be
described by prescribing member function (Select Initial Shape()). In the present investigation, only square
type is available as an initial billet geometry since it is
widely used for the shape rolling of bars. Member
data B represents the width of the material and can
be input by prescribing member function (Get Size()).
Member data area means the cross-sectional area of
the material, which can be determined automatically
by friend function (Area()) in the program.
2.2.2. FS class
This consists of the data representing the final
shape (type, B, area), member function (Select Final
Shape(), Get Size()) and friend function (Area()) similar to IS class. Member data type represents the
parameter indicating the final product geometry,
which can be described by prescribing member function (Select Final Shape()). In the present program
square and round shapes are available. Member data
B represents the size of the final geometry, which
can be described by prescribing member function
(Get Size()). For square and round shapes, the dimension of the side length and the diameter will be
prescribed, respectively.
Fig. 5. Searching the roll pass tree for the rolling of a square bar
based on backward chaining.
S.-H. Kim, Y.-T. Im / Journal of Materials Processing Technology 8990 (1999) 145151
149
3. Applications
Table 1
Structure of PSDB rule-base used in roll pass designing
Node (i-th pass)
Rotation (Deg.)
Round
Oval
90
Oval
Square
Box
Round
45
90
90
Square
Diamond
Oval
90
90
Diamond
Square
Oval
Box
90
90
90
Box
Fig. 7. Display of the area reduction at each rolling step for the
rolling of a square bar.
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S.-H. Kim, Y.-T. Im / Journal of Materials Processing Technology 8990 (1999) 145151
Fig. 8. Display of the roll separating force at each rolling step for the
rolling of a square bar.
The roll profiles used for manufacturing the cylindrical bar are given in Fig. 11(a). They ave produced a
round bar of diameter 0.225 in. from the initial square
billet of 1.125 1.125 in2 through 11 passes. In Fig.
11(b), the process sequence obtained from the developed program for the same geometry is given. According to this result, the total number of passes was
reduced from 11 to 10.
By comparing the two figures it was determined that
the squareovalsquare pass is favorable as before and
the two results are almost similar except for the initial
stage.
In Fig. 11(a), two oval passes were used: however,
these two stages were merged into one oval pass in Fig.
11(b). This might be due to the conservative design
practice used in industry to reduce the roll separating
force and possible lap formation. Other than this, it can
be construed that the developed system reasonably
Fig. 10. Display of the roll separating force at each rolling step for
the rolling of a round bar.
S.-H. Kim, Y.-T. Im / Journal of Materials Processing Technology 8990 (1999) 145151
151
Acknowledgements
The authors wish to thank the Grant from the Korea
Science Foundation (95-0200-14-04-3), under which this
research work was possible.
References
Fig. 11. Comparison of pass sequences for bar rolling between: (a)
practice (unit: inch); and (b) the developed system (unit: mm).
4. Conclusions
The knowledge-based expert system for determining
the roll passes and profiles for the shape rolling of
square and round bars from a square billet has been
developed with C + + language and object oriented programming. From applications of the developed program, the following conclusions are obtained:
1. The design knowledge-base was constructed from
interviews with the design engineers and existing
references.
2. Based on such a knowledge-base, the backward
chaining algorithm was developed to automatically
determine the intermediate roll passes. The practical
application demonstrates that the square oval
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