Rolling (metalworking)
Shape rolling design

Rolling mills are often divided into roughing, intermediate and finishing rolling cages. During shape rolling, an initial billet (round or square) with edge of diameter typically ranging between 100 and 140 mm is continuously deformed to produce a certain finished product with smaller cross section dimension and geometry. Starting from a given billet, different sequences can be adopted to produce a certain final product. However, since each rolling mill is significantly expensive (up to 2 million euros), a typical requirement is to reduce the number of rolling passes. Different approaches have been achieved, including empirical knowledge, employment of numerical models, and Artificial Intelligence techniques. Lambiase et al. validated a finite element model (FE) for predicting the final shape of a rolled bar in round-flat pass. One of the major concerns when designing rolling mills is to reduce the number of passes. A possible solution to such requirements is the slit pass, also called split pass, which divides an incoming bar in two or more subparts, thus virtually increasing the cross section reduction ratio per pass as reported by Lambiase. Another solution for reducing the number of passes in rolling mills is the employment of automated systems for Roll Pass Design as that proposed by Lambiase and Langella. subsequently, Lambiase further developed an Automated System based on Artificial Intelligence and particularly an integrated system including an inferential engine based on Genetic Algorithms a knowledge database based on an Artificial Neural Network trained by a parametric Finite element model and to optimize and automatically design rolling mills.
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