Shape rolling is widely used in producing uniform cross sectional parts of structural and mechanical elements due to high productivity and good product quality. However, the difficulties in predicting three-dimensional deformation and the related data such as roll separating force have made empirical design inevitable. Therefore, process design costs have been very high in terms of time and labor. In order to cope with the problem, design support system using PCs, which can provide calculation accuracy, high calculation speed, good graphic capabilities, has been developed.
In this study, a Computer-Aided-Design system for roll pass and profile design in bar rolling was developed. The system was developed based on C++ programming language in DOS environment. Interactive design method was used in the system to provide various design examples from which decision for optimal design can be made. To assist the interactive design process effectively, many reliable design data should be provided in a table form and a graphical display. At first, material flow for various roll profiles is visualized by applying a reliable spread prediction formula available in the literature. Based on the designed roll profile, roll speed at each stand for a continuous production is calculated. For accurate prediction of temperature, an approximate temperature prediction model was introduced. Finally roll separating force, roll torque and required motor power are calculated by using a flow stress formula, applicable to wide range of rolling conditions. In addition to the above data, the system provides empirical design formula and database for roll profiles in practice. Moreover, designed process by the system can be stored as a process database and can be used to assist the next process design. By applying the system, various processes are designed for a given product in a short time. The system can be an effective tool in designing rolling process and can minimize trial and error in design process in the industry.
