High-Order Groove-Shape Curve Roll Design for Aluminum Alloy 7075 Wire Rolling
Round 1
Reviewer 1 Report
This manuscript deals with the finite element analysis of a two-pass wire rolling process in which two type of groove cross section (elliptical, Bezier) are considered. Several analysis outputs were presented (torque, equivalent stress and strain, compressive force, wire dragging force).
This document is more like a technical report rather than a scientific article. Apart from the huge number of misprints (I counted ten just in the first page of Introduction!), it is not really clear what the “scientific gap” and original contribution is if compared to the existing literature. In its present form, the text seems only to summarise the results of a calculation deign for a specific wire rolling set-up, which does not represent any special nor original contribution to justify publication.
Other more specific comments:
The text is full of typos and grammatical errors (a short list just from L35-50: Diamwter, wire broken, oprofile, wrie rolling, orund maybe not, station, larger the the area, establise, empirical, might results,…). This huge number of trivial errors disturbs the reading quite a lot and also demonstrates a careless attitude of the Authors in writing their manuscript – please note that the Reviewer is not a proof-reader. Be sure that all typos and misprints are fixed before submitting your manuscript.
The Abstract is too long (about 400 words, whereas a maximum of 200 words is permitted). Please make sure that the Abstract summarises only the relevant points and findings of your manuscript.
Introduction: after a short literature survey, the final part of Introduction terminates without providing the expected and necessary description of the problem being analysis and the goal addressed in this paper.
Section 2: please provide a short description of the wire rolling process and main process parameters at the benefit of not specialised readers – please note that Metals is about alloys, not metal forming operations;
Eq. (1): a minus sign is missing, or it is written as a subscript. Please double-check the whole text for such kind of typos;
Sec. 2.3 seems to long, as it basically describes a fitting operation of a given polynomial curve;
Sec. 2.5: although the paper is about finite element simulation of wire rolling, no description is provided of the finite element model, for example: geometry, type of elements, material properties, boundary conditions, etc. Please provide all the relevant information to allow the interested reader to perform on his own your simulations. By contrast, the results of converges analysis (Sec. 3.1) are totally irrelevant and must not be shown, since a converge analysis is only a preliminary phase to calibrate the model, it is not part of simulation results;
L160: why a value 0.6 of friction factor? How do you estimate it?
Sections from 3.2 to 3.6 list many results that simply appear not very striking, therefore it is not clear what is the original contribution that would make this article deserve publication
References: a total of nine References is really insufficient for a regular research article. More references should be added to provide an adequate background on the topic addressed in this paper, especially for what concerns the use of finite element analysis. The short list below may help:
Finite element simulation of profile rolling of wire. https://doi.org/10.1016/S0924-0136(03)00607-1
An analytical approach to asymmetrical wire rolling process with finite element verification. https://doi.org/10.1007/s00170-015-7940-2
Modeling and finite element analysis of rod and wire steel rolling process. https://doi.org/10.1016/S1005-8850(08)60078-X
A harmonic one-dimensional element for non-linear thermo-mechanical analysis of axisymmetric structures under asymmetric loads: The case of hot strip rolling. https://doi.org/10.1177/0309324716658415
Static and dynamic finite element analysis of 304 stainless steel rod and wire hot continuous rolling process. https://doi.org/10.1016/S1005-8850(08)60061-4
3D FE Analysis of Thermal Behavior of Billet in Rod and Wire Hot Continuous Rolling Process. https://doi.org/10.1016/S1006-706X(07)60007-7
On thermal stress and fatigue life evaluation in work rolls of hot rolling mill. https://doi.org/10.1177/0309324712445120
Roll profile design for shaped wire rolling with high aspect ratio. https://doi.org/10.1007/s12206-020-0813-0
Author Response
The misspelling and grammatical errors had been corrected carefully.
The length of the abstract had been modified and cut to 185 words.
The issues and the goals of the paper had been added at the end of the introduction.
The rolling and the wire rolling process were introduced in the section 2.1, the main parameters of the rolling process were also mentioned.
The minus sign is assigned with the subscript character which is not correct. The character type had been modified to give the correct expression of equation.
Sec. 2.3 is not only a fitting operation but also a groove design methodology description. The determination of the control points is very important to the groove geometry design. The authors had proposed the methods of how to determine/calculate the control points. This description is necessary to explain the concept of the groove shape design. The requirement of the area reduction of the wire rolling process was applied to determine the correct location of the control points.
The mesh type and size were described in more detail. The boundary conditions, and the symmetric boundary were also given in Sec. 2.5. The flow stress and the damage criterion were also described here.
The friction coefficient was determined according to the suggestion of reference 11.
The proposed groove design method of Bezier curve and the empirical equations obtained in this paper are very helpful to the wire rolling process and roller design.
More references were added to enhance the understanding of the rolling process and the issues of research and industry applications.
Author Response File: 
Author Response.pdf
Reviewer 2 Report
Changes in the surface quality of the wires after process would have been a nice addition to the paper.
The English language of the manuscript involves many spelling errors.
Author Response
Already revised graphical abstract and supplied.
More references had been added in the introduction section.
Miss spelling had been modified.
The main idea of this paper is to propose a new groove shape design method and compare with the conventional design method. So far, the idea was only validated via the CAE simulations. We are trying to make further study but the rolling machine is not ready yet for the experimental validation.
The magnitude and units of color bars had been described and modified.
Author Response File: Author Response.pdf
Reviewer 3 Report
The paper “High order roll groove shape curve design for aluminum alloy 7075 wire rolling” addresses the prediction of the rolling forces and the rolling torques required for the two-step wire rolling process. It is of interest and novelty, so I suggest considering it for publication after major changes:
- A graphical abstract would add interest to catch the eye
- Address novelty and extend citations on Introduction section
- Figure 1 miss spelling “Wire producgt” and diam symbols
- In the introduction please mention other works addressing FEM on AA7075 (see https://doi.org/10.1007/s00170-020-05816-7)
- Have you take into account dynamic recrystallization phenomena (see https://doi.org/10.1007/s43452-021-00194-7)
- You could evaluate the accuracy of the model some validation could be address or comparison with data from the literature (this is a significant absence on the paper)
- Please describe the magnitude and units of colorbars (As Ex Fig 7)
Overall, the paper is well organized and correctly presented after small changes I find nothing against its publication.
Author Response
The friction stress ratio had been examined to check the surface quality and the wire buckling defects.
The spelling errors had been modified.
Author Response File: Author Response.pdf
Round 2
Reviewer 1 Report
The revised manuscript has the Word text revisions activated and it also contains some text sections written in Asian language (not English). Overall, the text is a chaos and makes my review impossible.
Please upload a cleaned and readable Word file in which all changes are simply underlined with a different text color (red) or highlighted in yellow. Please also cite explicitly in the point-by-point answers where (Page + line number) the changes were made.
Author Response
The manuscript had been revised again carefully. The point-by-point answers are as follows,
Point 1: The text is full of typos and grammatical errors (a short list just from L35-50: Diamwter, wire broken, oprofile, wrie rolling, orund maybe not, station, larger the the area, establise, empirical, might results,…). This huge number of trivial errors disturbs the reading quite a lot and also demonstrates a careless attitude of the Authors in writing their manuscript – please note that the Reviewer is not a proof-reader. Be sure that all typos and misprints are fixed before submitting your manuscript.
Response 1: The misspelling and grammatical errors had been corrected carefully. The typing errors were corrected as shown in the Word track changes mode. Indeed, a huge number of trivial errors were made and had been modified in the renewed version of the resubmit manuscript. Please refer to Pages 1-16.
Point 2: The Abstract is too long (about 400 words, whereas a maximum of 200 words is permitted). Please make sure that the Abstract summarizes only the relevant points and findings of your manuscript.
Response 2: The length of the abstract had been modified and cut to 182 words. More than 14 lines were deleted to shorten the length of the abstract. The length of the abstract was cut to 12 lines. Please refer to Page 1 L9-20.
Point 3: Introduction: after a short literature survey, the final part of Introduction terminates without providing the expected and necessary description of the problem being analysis and the goal addressed in this paper.
Response 3: The issues and the goals of the paper had been added at the end of the introduction. Please refer to Page 2 L89-94.
Point 4: Section 2: please provide a short description of the wire rolling process and main process parameters at the benefit of not specialised readers – please note that Metals is about alloys, not metal forming operations.
Response 4: The rolling and the wire rolling processes were introduced in the section 2.1, the main parameters of the rolling process were also mentioned and described. Please refer to Page 1 L24-27.
Point 5: Eq. (1): a minus sign is missing, or it is written as a subscript. Please double-check the whole text for such kind of typos;
Response 5: The minus sign is assigned with the subscript character which is not correct. The type of character had been modified to give the correct expression of equation. Please refer to Page 3 L112.
Point 6: Sec. 2.3 seems to long, as it basically describes a fitting operation of a given polynomial curve;
Response 6: Sec. 2.3 is not only a fitting operation but also a groove design methodology description. The determination of the control points is the proposed groove geometry design procedure. The step-by-step description of the control points determination was proposed. This description is necessary to explain the concept of the groove shape design. The requirement of the area reduction of the wire rolling process was applied to determine the proper location of the control points. Please refer to Page 5 L149-167.
Point 7: Sec. 2.5: although the paper is about finite element simulation of wire rolling, no description is provided of the finite element model, for example: geometry, type of elements, material properties, boundary conditions, etc. Please provide all the relevant information to allow the interested reader to perform on his own your simulations. By contrast, the results of converges analysis (Sec. 3.1) are totally irrelevant and must not be shown, since a converge analysis is only a preliminary phase to calibrate the model, it is not part of simulation results;
Response 7: The mesh type and size of the FEM model were described in more detail. The boundary conditions, and the symmetric boundary were also given in Sec. 2.5. The flow stress and the damage criterion were also described here. The results of convergence analysis were not shown again. Please refer to Page 5 L178-190 and Figure 3 (Page 6 L194).
Point 8: L160: why a value 0.6 of friction factor? How do you estimate it?
Response 8: The friction coefficient 0.6 was adopted according to the suggestion of reference 11 ( refer to Page 2 L78-81). The manuscrip had been modified and L160 was changed to Page 5 L187-189.
Point 9: Sections from 3.2 to 3.6 list many results that simply appear not very striking, therefore it is not clear what is the original contribution that would make this article deserve publication.
Response 9: The proposed groove design method of Bezier curve and the empirical equations obtained in this paper are very helpful to the wire rolling process and roller design. The resuslts of the conventional round-oval-round and the proposed Bezier curve method were compared to understand the differnece had been made by the proposed method. The damage distribution of pass 2 for the Bézier curve groove shape design was more uniform than the other cases, the maximum damage value of the case D was less than theconventional round-oval-round desidgn method. Please refer to Page 4 L143-167 for the proposed groove design method and Page 10 L254-258 for the possibility of the industry striking.
Point 10: References: a total of nine References is really insufficient for a regular research article. More references should be added to provide an adequate background on the topic addressed in this paper, especially for what concerns the use of finite element analysis. The short list below may help:.
Response 10: Thirteen references were reviewed to enhance the understanding of the rolling process and the issues of research and industry applications. Please refer to Pages 1-2 L35-89 for the paper review and Pages 16-17 L347-371 for the reference list.
Author Response File: Author Response.pdf
Reviewer 3 Report
It seems that the suggested revisions have been taken into account although the track changes format is not very easy to read from a pdf.
Author Response
The answeres to the reviewer's comments point-by-point and with page + line numbers are as follows,
oint 1: Changes in the surface quality of the wires after process would have been a nice addition to the paper.
Response 1: The friction stress ratio had been examined to check the surface quality and the wire buckling defects. Thanks for the suggestion. Please refer to Pages 259-271 for the description and Page 13 L338 Figure 9.
Point 2: English language of the manuscript involves many spelling errors.
Response 2: The misspelling and the grammatical errors had been corrected carefully. The typing errors were corrected as shown in the Word track changes mode. Indeed, a huge number of trivial errors were made and had been modified in the renewed version of the resubmit manuscript. Please refer to Pages 1-16.
Author Response File: Author Response.pdf
Round 3
Reviewer 1 Report
The revised paper has addressed my review comments. Only a few additional points are suggested here:
L89-94: it would be better to write this sentence on a new paragraph to give more emphasis on the paper goals;
L189 Please add proper reference and please explain what the Oyane damage model is;
Figure 5: the unit of measure of torque is Nm or N·m, not N-m;
L378-385: please cite these references according to the style specified in the Metals template (see Authors Guidelines)
Author Response
Response to Reviewer 1 Comments (round 3)
Point 1: L89-94: it would be better to write this sentence on a new paragraph to give more emphasis on the paper goals;
Response 1: A new paragraph had been used to address the industrial issues and the goals of the proposed paper. Please refer to Page 2 L90-95.
Point 2: L189 Please add proper reference and please explain what the Oyane damage model is;
Response 2: The characteristics of the Oyane damage criterion and the referencwere described, the reasons of using Oyane damage model in the simulation were explained, too. The Oyane damage criterion was cited in reference [14]. Please refer to Page 2 L95-99 for the explanation of Oyane damage model and Page 17 L394-395 for the reference information.
Point 3: Figure 5: the unit of measure of torque is Nm or N·m, not N-m;
Response 3: The units of the torque (Nm) and the rolling force (kN) in all figures were checked and modified if necessary. Please refer to Page 7 L22 Figure 5, Page 15 L360 and L362 Figurs 11 and 12, Page 16 L364 and L365 Figurs 13 and 14.
Point 4: L378-385: please cite these references according to the style specified in the Metals template (see Authors Guidelines)
Response 4: The format of the references cited were check and modified if necessary according to the style specified in the Metals template.. Please refer to Page 17 L370-395.
Author Response File: Author Response.pdf
