Predictive Hybrid Model for Process Optimization and Chatter Control in Tandem Cold-Rolling

Featured Application: The proposed hybrid model provides a predictive tool for chatter prevision and process optimization in multi-stand cold rolling mills. It enables the identification of stability margins and supports adaptive control strategies for high-speed rolling operations. Chatter is a self-excited vibration that limits productivity, accelerates roll wear and compromises strip surface quality in high-speed tandem cold-rolling. This work presents a predictive hybrid model that couples the strip-deformation physics to the structural dynamics of a five-stand, 4-high mill, providing a fast decision tool for process optimization and real-time control. The model represents each stand as a four-degree-of-freedom mass–spring–damper system whose parameters are extracted from manufacturing automation datasheets and roll-gap sensing. Linearization about the nominal point yields analytical sensitivity matrices that close the electromechanical loop; the delay between stands is also included in the model. Implemented in MATLAB/Simulink, the computational model, based on data provided by Danieli & C. Officine Meccaniche S.p.A., reproduces the onset of chatter for two types of steel. The framework therefore supports automation-ready scheduling, active vibration mitigation and design-space exploration for next-generation mechatronic cold-rolling systems.