Utilization of response surfaces in the optimization of roll-pass design in hot-rolling

The hot-rolling process is a very intense energy-consuming process, and deformation energy is one of the major cost items. The deformation energy consumed in the hot-rolling process is highly related to the design of the roll-pass sequence. In this study, the response surface methodology has been utilized to optimize minor geometric parameters – namely, radii and angle – in a box-pass design. Set values of the independent variables of the constructed response surface have been determined by central composite design. Simulation experiments based on the finite-element method have been carried out to estimate deformation energies. The methodology used in the simulations has been verified by modeling an industrial production process and comparing the simulation results with the industrial data. Optimization has been verified by applying the optimized radius and angle values to a roll-pass sequence with five stages. A decrease in deformation energy by 7.44% has been established by optimization with respect to conventional roll-pass design.