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To maximize the throughput of a hot rolling mill,
the number of passes has to be reduced. This can be achieved by maximizing the thickness reduction in each pass. For this purpose, exact predictions of roll force and torque are required. Hence, the predictive models that describe the physical behavior of the product have to be accurate and cover a wide range of different materials.
Due to market requirements a lot of new materials are tested and rolled. If these materials are chosen to be rolled more often, a suitable flow curve has to be established. It is not reasonable to determine those flow curves in laboratory, because of costs and time. A strong demand for quick parameter determination and the optimization of flow curve parameter with minimum costs is the logical consequence. Therefore parameter estimation and the optimization with real data, which were collected during previous runs, is a promising idea. Producers benefit from this data-driven approach and receive a huge gain in flexibility when rolling new
materials, optimizing current production, and increasing quality. This concept would also allow to optimize flow curve parameters, which have already been treated by standard methods. In this article, a new data-driven approach for predicting the physical behavior of the product and setting important parameters is presented.
We demonstrate how the prediction quality of the roll force and roll torque can be optimized sustainably. This offers the opportunity to continuously increase the workload in each pass to the theoretical maximum while product quality and process stability can also be improved.
Sequential Parameter Optimization is a model-based optimization methodology, which includes several techniques for handling uncertainty. Simple approaches such as sharp- ening and more sophisticated approaches such as optimal computing budget allocation are available. For many real world engineering problems, the objective function can be evaluated at different levels of fidelity. For instance, a CFD simulation might provide a very time consuming but accurate way to estimate the quality of a solution.The same solution could be evaluated based on simplified mathematical equations, leading to a cheaper but less accurate estimate. Combining these different levels of fidelity in a model-based optimization process is referred to as multi-fidelity optimization. This chapter describes uncertainty-handling techniques for meta-model based search heuristics in combination with multi-fidelity optimization. Co-Kriging is one power- ful method to correlate multiple sets of data from different levels of fidelity. For the first time, Sequential Parameter Optimization with co-Kriging is applied to noisy test functions. This study will introduce these techniques and discuss how they can be applied to real-world examples.