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The ultimate goal in hot roll pass design is to manufacture a rolled product with the required dimensional accuracy, defect free surface, and mechanical properties. The proper selection of process parameters is crucial to meet increasing requirements for desired quality and geometrical properties of rolled products. Due to the complex behavior of the metal flow at high temperatures and the severe plastic deformations in shape rolling, most efforts that have been made so far only rely upon the practical experience gained by operators. The large number of variables involved and the difficulty in investigating the process characteristics, make the use of finite element (FE) tools an effective and attractive opportunity towards a thorough understanding of the rolling process. In this work, Design of Experiment (DOE) is proposed as a powerful and viable method for the prediction of rolling process parameters while reducing the computational effort. Nonlinear 3D FE models of the hot rolling process are developed for a large set of complex cross-section shapes and validated article under the terms of the CC-BY 4.0, which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are credited. size, diameter reduction (draught), and rolls angular velocity. The selected DOE responses are workpiece spread, effective stresses, contact stresses, and rolls reaction loads. Eventually, the application of Pareto optimality (a Multi-Criteria Decision Making method) allows to detect an optimal combination of design factors which respect desired target requirements for the responses.

The influence of pre‐strain on the tensile and fatigue properties of a dual phase DP600 steel was studied. The material was pre‐strained by uni‐axial tension in rolling and transverse direction. Thereafter, specimens were cut from the deformed plates in parallel or orthogonal to pre‐strain direction. It was found that pre‐strain increases yield and tensile strength. Results suggested that strain path change primarily affects the elastic‐plastic transition during early stage of reloading. Pre‐strained specimens showed an increase in high cycle regimes as a consequence of yield strength increment, irrespective of imposed pre‐straining direction. A modified stress life equation that accounts for pre‐strain was proposed and showed good agreement with experimental data. Bake hardening enhanced both tensile and high cycle fatigue resistance. Walker equation was successfully fitted to account for tensile mean stress. In low cycle fatigue, negligible influence of pre‐strain was observed due to cyclic softening and residual stress relaxation.

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