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Metal Data Model Development Projects


Application development




Client / Employer


Development of a roll pass design program based on the full set of roll pass models

With Excel worksheet and the spread models, the a roll pass design program was created during the GST 19" Mill roll pass design, and was then used for several other roll pass design projects.



Development of a Windows-based roll pass program for pass design up to 28 passes

An initial version of the roll pass software was developed to roll steel from square billet to round in up to 26 - 28 passes (depending on number of stands in the mill). The designs included roughing, intermediate and finishing passes. Developed with VB/VC++.

Metal Data


Development of an application to manage and populate Excel spread sheet onto the intranet web site by reading an excel file as a database

According to the requirements: (1) multiple users should be able to access the most current files, which may be updated frequently by those with privileges to update them; (2) Common users should not be allowed to change the file. The intranet web provided the right solution. The Excel file was displayed on the intranet website, with its look-and-feel exactly like Excel.



Development of an application to manage engineering drawing files and display the drawings (in AutoCAD format) on the intranet web screen

Requirements: (1) Some AutoCAD drawing should be accessible for view by multiple users; (2) Other files in the same storage location should not be viewed by all the people; (3) Viewable files should provide the most current version. The intranet web was the perfect solution, so an application was developed to load the selected drawing onto the intranet web.



Development of a software tool to populate PLC data directly onto web screens

Some people want to see the live data of the PLCs. PLC may have more data than Level 1 or Level 2, and the data from PLC were the original. An application was written to directly access PLC addresses for data. The application was also particularly useful in the debugging period for the Level 1 and Level 2 applications.



Development of a suite of web-based roll pass design programs - AutoForm to allow the web user to design roll pass automatically

This set of applications allowed the user to do roll pass design without existing experience. The user only needed to fill in the required mill operational data. Two sets of roll pass models were combined in the software: the first set, with few factors considered, to do the first assessment; and the second, with many factors, to perform the high quality design. The combination of the two steps with those two sets of models provides both speed and quality of the roll pass design. See www.meta4-0.com/rolldesign.

Metal Data


Development of a suite of web-based roll pass design programs - FreeForm for experienced roll pass designers

This set of roll pass applications were provided with more flexibility (freedom) for the roll pass designer, and the models covered more influence factors such as the tension influence on the spread and forward slip. This set of programs could design multiple passes (e.g. up to 28). The user could also select various design procedures for spread and for forward slip calculations. Data for all passes could be saved and reloaded. See www.meta4-0.com/freeform.

Metal Data


Development of a finite-differential program to determine temperature profile during mill production including rolling, air cooling and controlled water cooling

The web-based finite difference program was designed to predict temperature profiles (surface, center, average, middle, etc.) pass by pass, from the furnace dropout until the completion of the water-cooling and airbed cooling. The user could save the input data for all the stages on his local computer, and reload the saved data in the future by reading the saved file. Various optimization steps were done so that the program could run sufficiently fast. Running web-based numerical solution truly demonstrated the technical skills of Metal Data, both in mill process and IT aspects. See www.meta4-0.com/cool.

Metal Data


Development of stored procedures to prepare SQL server database data for the website www.meta4-0.com

Data from database was loaded to the web by running stored procedures, so the internet user had only the right to run the pre-written stored procedures, and could not query through the database. This was critical for data security in the internet applications.

Metal Data


Development of a graphical program to display trend of data in the database (usually millions of records)

This tool was developed to quickly display major influence factors for the force error; it was also aimed at handling large amount of data (about a million records), for which graphical drawing with Excel was not efficient.



SQL script development to query data from Level 2/Level 3 database to send to local SQL Server

For automatic query of data from OSM's Informix database for needed data. Data was queried into local SQL server for further processing and evaluation.



Development of SQL scripts for data calculation and transformation (for force error calculation, data rounding, data selection, etc)

These scripts were to calculate errors, to transform data or to select certain data inside the SQL Server. For example, to study the influence of a factor (e.g. temperature), the other factors (e.g. strain) should remain unchanged. This is, however, impossible in the real, life data. What was done was to round the other parameters (e.g., to round 0.29 into 0.30 and 0.305 into 0.30). The rounding work was done inside SQL Server with SQL scripts.



Development of camber measurement, prediction and elimination system (proposed work plan for OSM Camber team)

Use cameras to measure the camber and then use the model to calculate the drafts for the two sides in the roll gap in order to adjust the roll gap in the two sides (with AGC) and to reduce or eliminate the camber.



Proposed solutions for several improvement opportunities

(1) OSM Level 2 Force Model Problem Solution (Work plan, 8 pages, for the meeting on Sept. 2006); (2) Development of OSM Material Processing System (Slab processing + Finish Processing. 16 pages); (3) OSM Reheating Process Improvement (8 pages); (4) Development of a Temperature Simulation System for OSM Heat Treating Furnace (13 pages); and (5) Prediction of Rolled Steel Properties (4 pages).



Development on Pass Manager Application

The program Pass Manager was developed. It is a program used to study total number of passes needed to roll a size, or the size range that can be rolled after certain number of passes. This is also a tool to examine whether a mill is operated in an efficient manner and whether it's feasible to roll new sizes or new grades. The program is developed to satisfy the industry need in collaborate with the Ask a Question in Metal Data Consulting section.

Metal Data

    Project Categories (Notes)

     1.  Development on Level 2 Systems & Libraries/Packs
     2.  Support on Level 2 Systems/Models/Logics
     3.  Product properties improvement
     4.  Application development
     5.  Productivity Improvement
     6.  Design & Development
     7.  Process Modeling - Numerical
     8.  Process Modeling - Empirical
     9.  Shape and yield improvement
    10. Web and Web Resource


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