Optimization of Seamless Flatness Roll Laser Cladding Process Using Finite Element Method and Response Surface Methodology

The seamless flatness roll is a critical inspection device in cold-rolled strip flatness control systems. Prolonged service causes cracks and scratches on the roll surface, while repeated grinding gradually removes the hardened layer, potentially rendering the roll unusable. To address the risk of thermal damage to internal sensors during the laser cladding repair of seamless flatness rolls, this study proposes a process optimization strategy using the Finite Element Method (FEM) and Response Surface Methodology (RSM). Focusing on an 820 mm roll, a regression prediction model for laser spot and internal component temperatures was constructed using a Box–Behnken design (BBD) based on an experimentally calibrated FEM model. Multi-objective optimization determined the optimal process parameters: laser power of 1.43 kW, laser radius of 3.73 mm, scanning speed of 23.45 mm/s, and overlap rate of 50.40%. Under these conditions, the average error between the predicted and experimental results was only 4.14%. The results confirm that the optimized process ensures the formation of a molten pool while maintaining internal components within safety thresholds, validating the feasibility of this non-destructive repair method.