Surrogate Modelling in Axles Rolling Processes

A surrogate analytical model was constructed and validated for deep rolling in train axle production. Two independent, distinct finite element models were developed to simulate both the time evolution and the stationary solution of this cold forming process. To reduce computational time, an efficient surrogate model was fitted that captures key features observed in the finite element modelling, such as the hardening relay and a maximum in the forming force characteristics as a function of feed rate. A measurement setup was developed for validation with pull-off roller ditch depth measurement.