Structural optimization of a Transversal Rolling Mill Component to Improve Flexional Stiffness

Carlo Bergamelli (Tenaris Dalmine)

CHALLENGE - This work analyzes the bar sustaining a plug, a component of the expander mill, to understand if an increased stiffness of a structural component of the transversal mill (the bar) can bring some effects in the product by stabilizing the process. The team must solve to increase the stiffness of the bar trying to keep the mill set up stable. The plug position deviates from the mill center because of the lamination forces and gravity. The new bar stiffness can be introduced in a explicit mill simulation model to calculate the effect on plug deviation loaded by the mill forces generated by disks and plug contact.

SOLUTION - An optimization tool is used to achieve the target in a proper and fast way. A 3D FEM model is developed to perform several different static analysis as basis of optimization process. The bending response of the structure is studied on the basis of the real working condition introducing the loads measured in the plant. An explicit model is then used to simulate the new stiffness in the expanding roll process.










BENEFITS | The results of Explicit simulations suggest an effective influence of the bar stiffness on the behavior of the machine in terms of dynamic equilibrium. modeFRONTIER saved designers from the high costs of creating physical models. With MOGA-ll, engineers at Tenaris were able to optimize their baseline design by analysing 380 genetic generations. The improvement for the optimized solution is around 45% in stiffness, keeping the mass in the constraint range.