Energy–Quality Balanced Optimization in Multi-Roll Leveling Parameters for Ultra-High-Strength Steel Considering Initial Wave Heights

In the leveling process of ultra-high-strength steel plates, sample scarcity—driven by high prototyping costs and small-batch production—coupled with a narrow and unevenly distributed feasible region due to high yield-to-tensile ratios and limited ductility, impedes the balanced optimization of plate shape quality and energy consumption. To address this issue, this paper develops an optimization framework for the balanced trade-off between these two objectives. First, a high-precision response surface model based on Box–Behnken experimental design and finite element simulation was constructed using initial wave height, entry roll reduction, exit roll reduction, and leveling speed as key process parameters; peak residual stress difference (characterizing potential sheet quality) and leveling energy consumption as co-optimization objectives; and post-leveling flatness as a constraint. Next, by introducing the NSGA-II multi-objective genetic algorithm, the Pareto optimal solution set for the quality and energy efficiency objectives was obtained, clearly revealing the trade-off relationship between the two; furthermore, the TOPSIS decision-making method was employed to select the comprehensive optimal process scheme that achieves a balance between quality and energy efficiency from the Pareto solution set. An adaptive recommendation curve for the leveling process parameters of MS1500 ultra-high-strength steel plates was established, covering an initial wave height range of 10.5–14.6 mm, thereby enabling intelligent parameter matching based on different incoming material conditions. Finally, industrial validation demonstrated that this optimized scheme significantly reduced leveling energy consumption while ensuring that post-leveling flatness meets the high-quality requirement of less than 3.5 mm·m−1. This achieves a balanced optimization of quality and energy efficiency. This study provides a reliable theoretical basis and practical engineering solution for the efficient and environmentally friendly leveling production of ultra-high-strength steel.