For years, Metal Pass has provided
consulting services on Level 2 model development or improvement, steel mill
software application development, roll pass design and other steel mill
Do I Need Help? - The
Level 2 Model Issues
Check whether your Level 2
system has involved any of
the following issues, and
whether you are a bit
confusing on the Level 2
Model Basics. If any of the
answers is Yes, you may need
help. We may spend only half
an hour for you, by running
our remote diagnosis tool
against your data and tell
you the problem(s). Most
likely you can fix it
yourself; if you want us to
do it, we will guarantee our
work's quality and your
Level 2 Model Basics
Metallurgical Issues in Level
Modeling Issues in Level 2
Software Engineering Issues in
Next-Generation Level 2 System
If you have interest in
handling such issues, you
may request some technical
papers we published in the
industry conferences with
our work examples.
Send us an email and
indicating who you are.
Metal Pass Recent
Technical papers published
Work List -
Mill Related Projects
in MS-Word Format)
Level 2 Development
Level 2 Support
Mechanical properties improvement
Mill Application Development
Rolling and Roll Pass Development
Rolling Process Modeling - Numerical
Rolling Process Modeling - Empirical
Shape and yield improvement
Web and Web Resource (14
Metal Pass Work Area
2 model improvement
Rolling mill Level 2 force model improvement. Many
Level 2 force model use simple formula and thus only reach limited
accuracy. Some system, such as Tippins Level 2, are even with design
error in adaptive learning. A summary of the work for a client:
Improvement on Level 2 Model Force Prediction is available as example.
A 10-page stage report for a company ("Company A") with a reversing/steckle
mill to roll plates and coils is also available. See stage 1 report
www.Meta4-0.com/consulting/FceModelRpt.doc and the report
for stage 2 www.Meta4-0.com/consulting/FceModelRpt2.doc.
Rolling mill Level 2 temperature model
improvement. We provide accurate model for heat transfer coefficients for every
heat transfer stage. For example, the heat transfer during rolling in the
roll gap depends on roll and stock materials, roll RPM, pressure, descaling
procedure and roll cooling, etc. The heat transfer coefficients in the
inter-pass or during traveling on the run-out table depends on relative speed
between stock and air, etc. We also integrate those models into your
temperature learning procedure.
Controlled cooling Level 2 system for water cooling. After evaluation of nearly
10 site testing reports we have developed accurate model on heat transfer
coefficients during controlled water cooling. The model can greatly increase
prediction accuracy for the controlled cooling system. We also have developed a
finite differential method (FDM) model which has great advantage over the
traditional slab element method.
mill application development
Metal pass has developed a long list of steel mill
process model based applications. A summary of the applications is available:
We develop model-based mill applications for flat rolling and shape rolling,
either hot or cold forming. We also develop programs for controlled water
cooling, reheating, EAF/LMF steelmaking, and Casting, etc.
We are developing a program package to predict rolled product properties.
Process models and system learning will be combined. For example, the grain
size at the entrance of the controlled water cooling in the run-out table can
be used as learning parameter. A proposal for the package development is
available: Prediction of Rolled Steel Properties.
We are also looking for industrial partner(s) to develop Enterprise Roll Pass
Software. See Proposal Part 1,
Part 2, Part 3,
and Part 4.
Microstructure prediction during steel rolling and cooling
automation system development
Strip, plate and coil shape control system
development. One Preliminary Proposal for Camber Problem
Solution is showed as example.
Level 2 Supervisory System: Design, development,
implementation, etc., Level 2 system for EAF, LMF, Caster, Rolling Mill,
Baghouse, and so on. A
short introduction of the Level 2 projects
completed is available.
Level 3 Automation: Design, development,
implementation, etc. Both Oracle and SQL Server as back end.
Plant-wide Application Development: data communication, data
management, production management, roll management, etc.
Process model development
Rolling Mill, Metal flow: Spread prediction
(critical for roll pass design), Forward slip, Roll work diameter, Roll
effective diameter, stock speed, etc.
Rolling Mill, Load and power requirements: Flow stress, Roll separating force,
Torque, Power, etc.
Rolling Mill, Microstructure: Dynamic and static recrystallization, Grain size,
Grain growth, etc.
EAF/LMF Steel making: Temperature prediction, Alloy addition, etc.
See the list of available process models for steel mill.
Wire rod rolling, bar rolling,
etc. Possess one of the best process models for roll design in this field.
Section rolling: Angle, I-beam, U-section, etc. With
research experience, have a book
and other publications
in this field.
Finite element analysis for rolling processes
(Section rolling, flat rolling, rolling with liquid core, etc.).
See topic summary of a Ph.D. project.
Finite element analysis for rolling other metal
forming processes (forging, extrusion, drawing, sheet forming, etc.).
Finite differential method for temperature prediction.
See web-based FDM program.
See consultant profiles for
Benjamin Li and
Dr. John Nauman. Please contact
us via email
email@example.com or by phone (0086)
13400064848 for top quality consulting