The optimization of accuracy and efficiency for multistage precision grinding process with an improved particle swarm optimization algorithm

Zhanying Chen,Liping Wang,Yiming Rong,Sheng Jiang,Zongyu Zhu,Zeming Zhao,Xuekun Li

doi:10.1177/1729881419893508

Zhanying Chen, Liping Wang + Show 5 more

Open Access

https://doi.org/10.1177/1729881419893508

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Abstract

For metal rolling, the quality of final rolled productions (for instance, metal sheets and metal foils) is affected by steel roll’s cylindricity. In roll grinding process, grinding parameters, which typically involve multiple substages, determine the steel roll’s quality and the grinding efficiency. In this article, a modified particle swarm optimization was presented to dispose of roll grinding multi-objective optimization. The minimization of steel roll’s cylindrical error and maximization of grinding efficiency were optimization objectives. To build the correlation between grinding parameters and cylindrical error, the response surface model of cylindrical error was regressed from the operation data of machine tool. The improved particle swarm optimization was employed to the roll grinding parameter optimization, and the optimal compromise solutions between grinding efficiency and cylindrical error were obtained. Based on the optimal compromise solutions, engineers or computer were capable to determine the corresponding most efficient roll grinding parameters according to the requirement of the final cylindrical error specification. To validate the efficacy of the improved particle swarm optimization, the validation experiment was carried out on the practical roll grinding operation. The error between the calculated optimized cylindrical error and experimental cylindrical error is less than 7.73%.

Highlights

In the process of rolling metal products, steel roll is a key component.[1,2] Cylindrical error is a significant specification of steel roll, and the unqualified cylindrical error of steel roll can cause the unqualified flatness error of the rolled metal sheets and even the fracture of rolled aluminum foil
Experimental results exhibit that the error between calculated optimized cylindrical error and experimental cylindrical error is less than 7.73%
The results indicated that the damage locations and extents were capable to be identified accurately by optimizing the objective functions with Particle swarm optimization (PSO)

Summary

Introduction

In the process of rolling metal products, steel roll is a key component.[1,2] Cylindrical error is a significant specification of steel roll, and the unqualified cylindrical error of steel roll can cause the unqualified flatness error of the rolled metal sheets and even the fracture of rolled aluminum foil. All stages’ parameters need to be planed appropriately to achieve cylindrical error criteria under maximum grinding efficiency. The quality criteria are achieved generally at the cost of time To change this situation, machining parameters planning method based on inputand-output model and intelligent optimization algorithm are introduced by researchers.[6,7] The input-and-output model associates machining parameters with qualities. The minimization of steel roll’s cylindrical error and maximization of grinding efficiency were optimization objectives. With developed modified PSO, optimal compromise solutions between grinding efficiency and cylindrical error were achieved. Based on the optimal compromise solutions, engineers or computer were capable to determine the corresponding most efficient roll grinding parameters according to the requirement of final cylindrical error specification. Experimental results exhibit that the error between calculated optimized cylindrical error and experimental cylindrical error is less than 7.73%

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