The intermittence of the shape detection signal associated with an entire roller-embedded shapemeter roll, used in a seven-pass cold reversible rolling process, is considered. A transient interference at the sensor top surface and the distance between the sensor top surface and the roll outer surface are developed, and a sensor reliability evaluation model is derived. The reliability of the sensor is evaluated via the random perturbation method, and the reliability sensitivity of design variables is proposed. The analysis reveals that the reliability is smallest in the third rolling pass. Of the design variables considered, the initial interference exhibits the largest reliability sensitivity and has the greatest influence on the sensor reliability. A reliability robust design model of the initial interference is therefore developed. A new shapemeter roll is fabricated and tested in a 1050 reversible cold rolling mill. The test results are consistent with the theoretical results, thereby validating the proposed model. The selection of an appropriate initial interference provides an important means of overcoming the adverse effects associated with the thermal deformation of sensor contact surfaces.
Based on the stress-strength interference model, the safety factor of traditional mechanical design method is introduced into reliability design theory and the new concept of reliability safety factor is extracted. Then a new design method based on the reliability safety factor is established. The reliability safety factor design method can effectively avoid the blindness and conservatism of traditional design method, and can also reduce the complexity of general reliability design method. When stress and strength are subordinated to various distributions, the reliability safety factors and reliability values are calculated and relevant design formulas are presented. The actual application to mechanical design proved that the new reliability design method is feasible and useful to improve the design level and reduce the cost.
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.