Robust optimization of the energy efficiency of the cold roll forming process

This paper proposes a hybrid modeling methodology for the robust optimization of cold roll forming process parameters. Energy efficiency is considered with the utilization of both analytical and computational models. A robust design algorithm is developed for the calculation of the optimized energy efficiency indicator through an analytical model at a low computational cost. The calculated optimum energy efficient solution is validated by a finite elements model (FEM) under specific quality constraints: the mapping of longitudinal strains, along a roll forming direction and a cross-sectional distribution, major strains on FLD, profile thickness reduction, and cross-sectional dimensional error. A robust design optimization towards the energy efficiency of a U-channel profile is demonstrated, and the effect of process parameters on the energy efficiency indicator is calculated. The paper arrived at the conclusion that the factors with the dominant effect on energy efficiency are roll gap, roller radius, and bending angle concept, with 30.96, 24.77, and 23.62 % contribution, respectively. Verification of the quality constraints over FEM has proven the feasibility of the optimum solution.