Interactive computer-aided-design system for roll pass and profile design in bar rolling

In this study, a computer-aided-design (CAD) system to support roll pass and roll profile design of bar rolling, where simple shapes like round and square bars are produced, was developed in order to minimize trial and errors in industry. An interactive design methodology was used in the developed system to provide various design examples from which decisions for an optimal design can be made. In addition, an algorithm for generating automatic roll pass design of local passes was proposed. In order to effectively assist the interactive design process, material flow and engineering data such as roll separating force and required power, based on reliable empirical formulas, were calculated and displayed. For more accurate engineering calculations, roll speed was calculated for continuous rolling and an approximate heat transfer model was proposed. Finally, the developed system was applied in the process design for rolling a square bar. It was found that the system will improve the efficiency of designing process by reducing time and cost.