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Abstract
This paper presents a systematic design procedure for the design of a laboratory cold rolling mill. In order to arrive at proper decisions at
various stages of the design, the concepts of fuzzy sets and priority decision tables were employed. The design process starts from deciding
specications and gradually reaches the detailed design phase. Specications were xed by trading-off various conicting goals using the
fuzzy set-based methodology. The various factors to be considered for deciding the roll diameter are presented. The roll diameter and motor
power are chosen using the fuzzy set-based technique. Three possible arrangements for transmitting the power to rolls were conceived. The
best among these three design alternatives was chosen by preparing a priority decision table. After the conceptual and embodiment stages of
the design, the detailed design was carried out in a conventional way. The present paper gives more emphasis to a systematic design
procedure for the conceptual and embodiment stages in the design process. # 2002 Elsevier Science B.V. All rights reserved.
Keywords: Rolling; Fuzzy set; Priority decision table; Design methodology
1. Introduction
Design of a rolling mill is a complex task requiring
thorough understanding of the process as well as good
decision-making capability for satisfying various conicting
goals. Numerous investigations have been carried out for the
analysis of the rolling process. For a brief review of representative papers, one can refer to the paper by Dixit and
Dixit [1]. However, to make use of these ndings of rolling
process analysis in design is not an easy task. In the process
of rolling mill design, the mill designer chooses appropriate
analytical tools, searches for empirical relations if analytical
methods are not fully developed or analysis time is a
constraint, makes use of his experience and then keeps
taking decisions at various stages of the design.
The design process starts from deciding the specication
of the product. In the beginning, the specications are
allowed to have a certain amount of exibility and they
gradually crystallize to crisp form as the design progresses.
Three important stages of the design are: conceptual design,
embodiment design and detailed design. Conceptual design
takes the problem statement and generates broad solutions
for it in the form of design concepts. In the context of a
rolling mill, it is the stage where the designer decides about
the type of roll arrangements, suitable roll-drive mechanism,
motor type, etc. At the embodiment stage, the concepts are
converted into bodily form. This is also called preliminary
*
Corresponding author.
0924-0136/02/$ see front matter # 2002 Elsevier Science B.V. All rights reserved.
PII: S 0 9 2 4 - 0 1 3 6 ( 0 1 ) 0 1 2 0 1 - 8
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During the last three decades, fuzzy set theory has been
nding wide applications in various elds of engineering
including decision-making in design. It was introduced by
Zadeh [3] to model real complex systems which are difcult
to model with conventional set theory. In the conventional
crisp set, a member either belongs to, or does not belong to,
a set. On the other hand, in the fuzzy set, the individual may
be a member of the set to varying degrees. The degree to
which that individual is compatible with the concept represented by the fuzzy set is called its membership grade in the
set and is usually represented by a real number value
between 0 and 1, 0 indicating full non-membership and 1
indicating full membership. Wood and Antonsson [4,5]
presented a fuzzy set-based method (called method of
imprecision, MoI). The MoI uses the concept of fuzzy set
theory to represent the designer and customer preferences in
the form of a fuzzy set. Thruston and Carnahan [6] have
prescribed the use of fuzzy set and utility analysis techniques for evaluation of multiple attributes in the preliminary
design stages.
Considering that the material parameters and friction
coefcient in the rolling process are uncertain, Dixit and
Dixit [1] treated them as fuzzy numbers. A fuzzy number is a
special type of fuzzy set dened on the set of real numbers
whose membership function is piecewise continuous. It is a
generalization of interval number in which the number may
lie in different intervals to varying degrees. The authors also
proposed the method to access the reliability of design. The
subsequent paper by the authors employed fuzzy set theory
in the scheduling of a tandem rolling mill [7].
The aim of the present paper is to describe a systematic
methodology for the design of a cold rolling mill, giving
more emphasis to the preliminary phases of the design, i.e.
the conceptual and embodiment phases. A vast amount of
literature is available on the detailed design aspects of
rolling mills [8]. In this work, a guideline has been presented
to apply the existing knowledge in a systematic and formal
way to arrive at the design, taking as an example the design
of a laboratory rolling mill which has been fabricated at the
Indian Institute of Technology, Guwahati.
2. Design methodology
Arriving at the design specication is the rst task in the
design process. After that the conceptual, embodiment and
detailed design stages follow. Quite often the decisions taken
at one stage are revised after getting more information about
the design in subsequent stages. The following subsections
describe the salient features of the design methodology
adopted for the cold rolling mill.
2.1. Decision regarding design specification
In arriving at a decision regarding the design specications, the following are the minimum required parameters:
1.
2.
3.
4.
5.
6.
1
1
r
h1
1 r
1
v ln s0 bh1
v ln
0:5r
1 0:5r
1 r
h2
(1)
U.S. Dixit et al. / Journal of Materials Processing Technology 121 (2002) 6976
71
Fig. 1. Membership function of desired: (a) velocity, (b) reduction and (c) power.
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U.S. Dixit et al. / Journal of Materials Processing Technology 121 (2002) 6976
decision was regarding the arrangement for power transmission from the gear box to the rolls. In the rolling mill, the
lower roll position was xed and the upper roll has to move
up and down for proper roll gap adjustment. At a meeting of
the designers at the concept phase of design, three possible
arrangements were conceived.
First arrangement (bevel gear drive arrangement) consists
of three pairs of bevel gears. First pair of bevel gears
transmits the power from a horizontal shaft of the main
motor to a vertical shaft. Second pair of bevel gears transmits
power from the vertical shaft to the xed lower roll. The last
pair of bevel gears transmits power from the vertical shaft to
the upper roll. This pair is connected to the vertical shaft
through a key and key-way arrangement so that it can slide
vertically along the shaft as the upper roll is displaced for
adjusting the roll gap.
The second arrangement (spur gear arrangement) consists
of four spur gears for transmitting power from the main shaft
to the rolls. The rst spur gear transmits power directly to the
xed lower roll. The same spur gear also transmits power to
the fourth gear attached to the upper roll. In between the rst
and fourth gears, there are two spur gears whose centres can
be moved along circular paths. This way, the upper roll can
easily be moved up and down for roll gap adjustment.
The third arrangement (universal joint drive arrangement)
consists of transmitting power to two working rolls by means
of universal joints and telescopic shafts. The telescopic shaft
consists of two parts. One part of the telescopic shaft consists
of internal splines through which the other part of the shaft
containing external splines can slide. This arrangement takes
care of the increase in the shaft length as the upper roll
moves during roll gap adjustment.
A priority decision table [9] was constructed to consider
the best among the three possible arrangements, as shown in
Table 1. First, various design criteria were chosen and their
importance was decided on a scale of 010, 0 indicating low
and 10 indicating high. For each criterion, the three design
alternatives were assigned a rating on the same scale as was
used in assigning importance. This was done in a brainstorming session of the designers. For each alternative, its
criteria rating was multiplied by the respective importance
factors, and all the resulting parts were added. Table 1 shows
the maximum score is achieved by the universal joints drive
Table 1
A priority decision table for choosing one amongst three design alternatives
Sl. No.
1
2
3
4
5
6
Total score
Alternatives
Criteria
Importance (I)
Ratings (Ra)
Design simplicity
Economy
Ease of assembly
Ease of maintenance
Efficiency of power transmission
Reliability
10
9
8
8
9
9
7
8
6
7
8
8
Ratings (Ra)
7
9
6
8
8
8
Ratings (Ra)
Ra I
10
9
8
8
8
9
100
81
64
64
72
81
462
U.S. Dixit et al. / Journal of Materials Processing Technology 121 (2002) 6976
73
Fig. 2. Membership functions of roll diameter from the viewpoints of low power and defect-free rolling process.
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h1 r
8m2m
(5)
t0
(6)
U.S. Dixit et al. / Journal of Materials Processing Technology 121 (2002) 6976
75
did not arise. The low, most likely and high estimates of
these parameters were taken as follows:
dm
(12)
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U.S. Dixit et al. / Journal of Materials Processing Technology 121 (2002) 6976