EAAI Journal 2026 Journal Article
Cascaded U-Net diffusion refiner for deformation prediction in hot strip rolling
- Han Gao
- Shanhong Cao
- Xueqi Dong
- Xu Li
- Feng Luan
- Dianhua Zhang
In the hot strip roughing process, Vertical-Horizontal rolling induces “fishtailing” deformation that leads to yield-reducing profile defects. While finite element method (FEM) simulations accurately model the complex elastoplastic deformation mechanisms underlying this phenomenon, their computational intensity impedes real-time process optimization and large-scale parametric analysis. To bridge this critical gap between accuracy and efficiency, we propose a Cascaded U-Net Diffusion Refiner (CUDR) framework for elastoplastic deformation prediction in hot rolling. The core design of this framework lies in the collaborative operation of two components: the U-Net first performs fast coarse prediction of deformation to provide a “warm start” foundation, and then the diffusion model conducts lightweight denoising refinement on the coarse prediction results. This refinement step primarily aims to suppress unphysical local fluctuations in the U-Net's predictions, thereby further enhancing the overall prediction precision. Validated on three orthogonal-sampled datasets with varying mesh resolutions, the CUDR reduces prediction errors by 26. 1% in Euclidean Mean Absolute Error and 28. 5% in Euclidean Mean Peak Absolute Error compared to the standalone U-Net. Moreover, Fourier-based spectral verification confirms that the framework suppresses unphysical local fluctuations. Critically, for fine-mesh cases, the CUDR achieves a 3900 times speedup over high-fidelity FEM simulations, making real-time deformation prediction feasible. This work demonstrates the substantial potential of generative diffusion models in advancing metal forming simulation, offering a new paradigm for balancing accuracy and efficiency in industrial manufacturing processes.