Optimization design of a novel X-type six-high rolling mill based on maximum roll system stiffness

Area of Science:

• Materials Science and Engineering
• Mechanical Engineering
• Manufacturing Processes

Background:

• Rolling mills are crucial for producing metal strips.
• Optimizing mill rigidity is essential for strip quality and process efficiency.
• Existing roll layouts present limitations in achieving maximum stiffness.

Purpose of the Study:

• To design and analyze a novel X-type six-high (X-6h) rolling mill.
• To compare the rigidity characteristics of X-6h, I-type six-high (I-6h), and four-high (4-h) mills.
• To optimize the roll gap stiffness of the X-6h mill through parameter adjustment.

Main Methods:

• Parametric modeling of 4-h, I-6h, and X-6h mill roll layouts.
• Three-dimensional (3D) finite element (FE) contact analysis under constant vertical load.
• Comparative analysis of stress and elastic deformation.
• Genetic algorithm (GA) optimization for backup roll (BUR) to work roll (WR) diameter ratios.

Main Results:

• The X-6h mill exhibits the highest roll gap stiffness among the analyzed configurations.
• Optimized diameter ratios for BUR and WR were determined using the GA.
• FE analysis provided insights into stress distribution and deformation under load.

Conclusions:

• The proposed X-6h mill design offers enhanced rigidity.
• The optimization method successfully identified optimal structural parameters for improved performance.
• A prototype X-6h mill successfully produced high-quality magnesium and aluminum alloy strips, validating the design.