Virtual
Rolling Mill

A phenomenon-based simulation core combined with AI-augmented optimization covering the entire rolling line from reheating through finishing and coiling, not just isolated stands.

STEP 1 | SIMULATION

PHENOMENON-BASED DIGITAL TWIN

High-fidelity, physics-driven modeling of every coupled phenomenon – thermal, mechanical, and metallurgical – across the rolling mill and the product itself.

STEP 2 | OPTIMIZATION LOOP

AI-AUGMENTED ALGORITHMS

Iterative parameter tuning that drives the simulation core directly, automatically converging on throughput, material properties, and quality targets.

STEP 3 | PREDICTIONS

ACTIONABLE PROCESS INSIGHT

Final predictions for loads, temperatures, microstructure evolution, and potential defects – delivered before single coil is rolled.

ENTIRE LINE COVERAGE

From reheating to coiling – One continuous twin

Every stage is solved with the same coupled physics core – so upstream decisions propagate downstream automatically, exposing interactions that single-stand models never see.

REHEATING

ROUGHING

FINISHING

COOLING

COILING

FAQ

  • Our platform covers the full rolling process:

    •  Reheating

    •  Roughing

    •  CoilBoxing

    •  Finishing, Steckel

    •  Accelerated water-cooling

    •  Coiling

    •  Cold Rolling

    Rather than optimizing individual steps, we simulate and optimize the entire process as one system.

  • The simulations are based on high-fidelity physical models that resolve:

    •  Thermal boundary conditions

    •  Roll gap phenomena

    •  Microstructural evolution (e.g. recrystallization, grain growth, phase transformations)

    This ensures industrial-grade accuracy suitable for real production environments. The founders have long academic careers during which they have accumulated knowledge on the state-of-the-art models related to thermo-mechanical and metallurgical simulation. These models have been implemented into the Virtual Rolling Mill solver.

  • AI is used to enhance optimization, not replace physics.

    Optimization algorithms explore the process window and identify optimal parameter combinations, enabling:

    •  Faster convergence to optimal setups

    •  Improved material properties

    •  Fewer physical trials

  • Yes.

    • Engineers benefit from deep process insight and simulation detail.

    • Business leaders gain clear visibility into cost savings, efficiency gains, and ROI.

  • After submitting a request:

    1. Our team reviews your specific production challenges

    2. We prepare a tailored demo

    3. We schedule a session focused on your use case

    The demo shows how Virtual Rolling Mill can directly impact your process and result.

  • A Virtual Rolling Mill is a high-fidelity, physics-based digital twin of your rolling process.

    It simulates thermo-mechanical and metallurgical phenomena across the entire production line with industrial-grade precision, enabling accurate process prediction and optimization.

  • Unlike simplified or stand-alone models, our solution combines:

    •  Full thermo-mechanical simulation

    •  Detailed metallurgical modeling

    •  AI-augmented optimization

    This allows you to simulate the entire process from reheating to finishing and coiling with physical models, not just isolated process steps.

  • We combine a thoughtful, human-centered approach with clear communication and reliable results. It’s not just what we do—it’s how we do it that sets us apart.

  • With Virtual Rolling Mill, you can:

    •  Reduce or eliminate costly trial coils

    •  Shorten R&D lead times

    •  Improve process predictability and control

    •  Optimize product quality and material properties

    All of these contribute directly to improved mill performance and profitability.

  • By replacing physical trial-and-error with accurate virtual simulations, you can test and refine rolling parameters digitally before production. This minimizes unnecessary trials and reduces both material waste and production downtime.

Ready to eliminate trial coils and optimize your process?

Whether you are looking for a technical deep-dive or an overview of measurable benefits and cost savings, our team is here to help.

REQUEST A DEMO