gistfile1.txt

import re
import numpy as np
import pandas as pd
import matplotlib as mpl
import matplotlib.pyplot as plt
import pyroll.core
import pyroll.pillar_model
import pyroll.freiberg_flow_stress
from pyroll.freiberg_flow_stress import FreibergFlowStressCoefficients
# import pyroll.hill_spreading
# import pyroll.roux_spreading
import pyroll.sander_spreading
# import pyroll.sparling_spreading
# import pyroll.marini_spreading
# import pyroll.lendl_equivalent_method
import pyroll.lippmann_mahrenholz_force_torque
import pyroll.zouhar_contact
import pyroll.integral_thermal

# import pyroll.wusatowski_spreading
# @pyroll.core.SymmetricRollPass.wusatowski_material_coefficient
# def wusatowski_material_coefficient(self):
#     return 1

# @pyroll.core.SymmetricRollPass.wusatowski_friction_coefficient
# def wusatowski_friction_coefficient(self):
#     return 1.001
#     # return 1
#     # return 0.995


def create_groove(groove_name, grooves):
    groove = grooves.loc[groove_name]
    groove_name = groove_name.lower().strip(' ')
    groove_type = re.sub(r'[.\(\)\-0-9]', '', groove_name)
    if groove_type == 'box':
        shape = pyroll.core.BoxGroove(ground_width=groove['a'], usable_width=groove['A'], depth=groove['h'], r1=groove['r'], r2=groove['R'])
    elif groove_type in ['ov', 'ova', 'ovc', 'ove', 'ovf']:
        shape = pyroll.core.CircularOvalGroove(depth=groove['h'], r1=groove['r'], r2=groove['R'])
    elif groove_type == 'ovp':
        shape = pyroll.core.Oval3RadiiFlankedGroove(usable_width=groove['A'], depth=groove['h'], r1=groove['r'], r2=groove['R1'], r3=groove['R'], flank_angle=90 - groove['alpha'])
    elif groove_type == 'r':
        shape = pyroll.core.FalseRoundGroove(depth=groove['h'], r1=groove['r'], r2=groove['R'])
    elif groove_name.startswith('rd2') or groove_name.startswith('frd') or groove_name.startswith('bo'):
        shape = pyroll.core.Oval3RadiiGroove(usable_width=groove['A'], depth=groove['h'], r1=0.0, r2=groove['R1'], r3=groove['R'])
    elif groove_type == 'rf':
        shape = pyroll.core.Oval3RadiiGroove(usable_width=groove['A'], depth=groove['h'], r1=groove['r'], r2=groove['R1'], r3=groove['R'])
    else:
        shape = pyroll.core.FalseRoundGroove(depth=groove['h'], r1=0.0, r2=groove['R'])
    return shape

h0 = 160e-3

billet_property = {
    "temperature": 920 + 273.15,
    "freiberg_flow_stress_coefficients": FreibergFlowStressCoefficients(
             a=759.285 * 1e6,
             m1=-0.00358,
             m2=0.338339,
             m3=-0.055943,
             m4=0.000104,
             m5=-0.000599,
             m6=0,
             m7=-0.448028,
             m8=0.000198,
             m9=0.356106,
             baseStrain=0.1,
             baseStrainRate=0.1),
    "material": "Steel",
    "density": 7.8e3,
    "specific_heat_capacity": 6.9e2,
    "thermal_conductivity": 23,
    "strain": 0.0001,
}

in_profile = pyroll.core.Profile.box(
    height=h0,
    width=h0,
    corner_radius=3e-3,
    **billet_property
)

data = {
    'groove': ['BOX1-1', 'BOX2-1', 'BOX3-1', 'BOX4-1', 'OVP5-1', 'R6-1'],
    'A': [247.63, 175.56, 192.4, 130.0, 160.0, 108.32],
    'a': [202.6, 151.12, 158.0, 107.87, 0, 0],
    'h': [50.6, 54.0, 38.9, 46.0, 37.4, 44.0],
    'R': [30.0, 31.0, 21.3, 23.2, 205.9, 49.0],
    'R1': [0, 0, 0, 0, 30.2, 0],
    'r': [15.1, 15.8, 10.8, 11.7, 8.00, 10.0],
    'alpha': [24, 12.75, 23.61, 13.52, 30, 31],
}

index = ['BOX1-1', 'BOX2-1', 'BOX3-1', 'BOX4-1', 'OVP5-1', 'R6-1']
grooves = pd.DataFrame(data, index=index)
grooves.drop('groove', axis=1, inplace=True)
grooves = grooves/1e3
grooves['alpha'] = grooves['alpha']*1e3
groove = create_groove('OVP5-1', grooves)

data = {
    'stand': [1, 2, 3, 4, 5, 6],
    'groove': ['BOX1-1', 'BOX2-1', 'BOX3-1', 'BOX4-1', 'OVP5-1', 'R6-1'],
    'e': [43, 37, 29, 25, 12, 10],
    'r0': [0.375, 0.375, 0.325, 0.325, 0.325, 0.325],
    'vl': [0.158, 0.202, 0.285, 0.373, 0.531, 0.698]
}

stands = pd.DataFrame(data)
stands['e'] = stands['e']/1e3

stand_positions = {1: np.float64(0.0),
                   2: np.float64(3.8),
                   3: np.float64(7.0),
                   4: np.float64(9.2),
                   5: np.float64(11.4),
                   6: np.float64(13.6),}

roll_passes = []
for i in range (len(stands)):
    stand = stands.iloc[i]
    stand_diameter = 2 * stand['r0']
    groove = create_groove(stand['groove'], grooves)
    roll_pass = pyroll.core.RollPass(
        coulomb_friction_coefficient=0.3,
        disk_element_count=20,
        front_tension=0,
        back_tension=0,
        label=stand['groove'],
        roll=pyroll.core.Roll(
            groove=groove,
            nominal_diameter=stand_diameter,
            max_radius=stand['r0'],
            min_radius = stand['r0'] - groove.depth,
            poissons_ratio=0.3,
            elastic_modulus=1e11,
            rotational_frequency=stand['vl']/np.pi/stand_diameter,
        ),
        # velocity=stand['vl'],
        gap=stand['e'],
        rotation=False,
    )
    if i == 0:
        roll_pass.in_profile = in_profile

    # roll_pass.orientation = 'h' if i%2 == 0 else 'v'
    roll_passes.append(roll_pass)
    if i + 1 < len(stands):
        transport = pyroll.core.Transport(
            label= f"{stand['stand']}:T",
            duration=(stand_positions[stands.iloc[i + 1]['stand']] - stand_positions[stands.iloc[i]['stand']])/stand['vl'],
            cooling_water_temperature = 273.15 + 20,
            cooling_heat_transfer_coefficient=10,
            convection_heat_transfer_coefficient=50, )
        roll_passes.append(transport)
        rotator = pyroll.core.Rotator(
            # parent=roll_pass,
            label=f"Rotator:{i}",
            duration=0,
            length=0,
        )
        roll_passes.append(rotator)

sequence = pyroll.core.PassSequence(roll_passes)
rps = [s for s in sequence if isinstance(s,pyroll.core.DeformationUnit)]

def passwise_solve(sequence, in_profile0, start=0):
    for i in range(start, len(sequence)):
        try:
            if i > 0:
                in_profile = sequence[i - 1].out_profile
            else:
                in_profile = in_profile0
            print(f"try on pass {i}")
            sequence[i].solve(in_profile=in_profile)
        except Exception as e:
            traceback.print_exc() # Prints the full traceback to stderr
            # or, to get it as a string:
            # print(traceback.format_exc())
            print(f"solution faied at pass {i}")
            return i
    return i

sequence.solve(in_profile)
# start = 0
# start = passwise_solve(sequence, in_profile, start)