THE CONCEPT OF OPTIMAL BAR ROLL DESIGN. REPORT 2. CALIBERS SPACE

Using the ideas of systems concept and based on the experience of a theoretical study, design and industrial mastering of processes of section rolling of a wide range of profiles at the Chair of Metal Forming of Ural Federal University the universal “Concept of optimum calibration” was developed. The general ideology of optimization of roll pass design was explained in Report 1 of the article. Within the developed intention, concepts of the continuous and discrete space of calibers are considered. For creation of the discrete space of calibers it is offered to use a classification method. As measurements of calibers space are the most significant, simple and evident characteristics of calibers are used. As an example of use of the considered procedure, creation of the discrete space of rail calibers was executed. At the same time, as measurements (characteristics) of calibers space technological and geometrical features of rail calibers are used: T – caliber type on character and the purposes of forming, С – existence of axes of symmetry and P – provision of the connector of caliber rolls or quantity of the rolls forming caliber. Filling of calibers space was carried out in the course of structural analysis of working calibrations of the rolls known from literature and factory atlases of calibrations. The calibers space is presented in the form of the three-dimensional table reflecting a complete set of all possible rail calibers in the structured form. It was set that for each of the selected characteristics of calibers (T, С and P) the limited number of levels of variation exists (6, 4, 7, respectively). Geometrically it is possible only 97 combinations of levels of characteristics, each combination are single-digit defined by a type of specific rail caliber and has native formal code. Change in level of any characteristic in this table leads to transition in calibers space to other point of this space i.e. using caliber of other type. The present approach to the construction of calibers space can be used to create computer-aided design and optimization of roll pass design.

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