Development of energy-saving optimization for the oval-edging oval pass design using genetic algorithm

Abstract

In the multi-pass rod rolling systems, where the final products are round bars with different sizes, oval-edging oval passes are widely employed as intermediate passes. This study attempts to present a generalized strategy to support the optimal design of oval-edging oval passes. A design system based on this strategy is developed to minimize power consumption, to reduce trials and errors in industry, as well as to improve the design efficiency and flexibility. A series of equations are established for geometrical modeling and graphic plotting of oval-edging oval passes, which can realize the parametric transformation for roll pass design and optimization. A novel formula based on statistical analysis and data fitting is proposed for the calculation of power consumption. To verify this formula, results obtained are compared with those calculated from using the Smirnov’s formula. The comparison confirmed the accuracy and efficiency of this formula. Finally, the proposed approach is applied for the optimal design of oval-edging oval passes, which are widely employed for the intermediate passes in the rod rolling systems. Through the comparison between simulation results and experimental data from literature, it is concluded that the proposed method can reduce power consumption of these passes and is able to improve the efficiency and flexibility of intermediate pass design without compromising its accuracy.