A multi-objective optimization workflow of ring-rolling process parameters based on production energy and time

Our industrial era is characterized by a significant attention to environmental aspects and production sustainability. Under this point of view, the minimization of the process energy represents a milestone leading to a consistent reduction of pollution. However, to promptly react to the high production rate market request, companies employ time saving manufacturing strategies, often in contrast with this principle. Considering this, an optimization concerning the reduction of both production time and energy, results to be strategical, especially when energy-intensive processes, such as ring rolling, are considered. Ring rolling is a shaping process performed by a dedicated equipment, composed of a driving roll, an idle roll, and a couple of axial rolls, allowing to obtain seamless rings while simultaneously reducing their height and thickness, while enlarging diameter. The kinematics of each component of the equipment can be set independently. This leads to several process conditions influencing quality, energy, and times, and makes it difficult the selection of the most suitable configuration. In this paper, a multi-objective optimization workflow is presented. Starting from validated FEM simulation campaign results, the proposed methodology allowed to individuate the best process parameters combination for limiting energy and time, encouraging its application to a wider range of energy-consuming processes.