Abstract 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