Schedule

12–13 March 2026 • Hilton Indianapolis Hotel & Suites • Indianapolis, IN, USA

Thursday, 12 March 2026

Instructed by Mark Zipf, Aluminum Dynamics LLC

7 a.m.Breakfast
8 a.m.Introductions and Opening Remarks
Brian Smith, ANDRITZ Metals USA Inc.
8:05 a.m. Material Mechanics
The analytic physics of material deformation and flow in multiaxis loading are discussed. An examination of Cauchy’s deviatoric invariants develops the biaxial yield criteria in terms of Tresca and Huber-Von Mises criteria, along with the Levy’s plastic strain conditions. Mechanisms of work hardening and loading/unloading behavior are considered.
9 a.m. Mechanics of the Roll Bite
A review of classical definitions is followed by a step-by-step discussion on the forces, torques, friction and material flow within the roll bite. The force-loaded roll gap geometry (roll flattening) is then examined leading to the formation of the pressure distribution.
10 a.m. 
Break
10:15 a.m. Dissection of the Circular Arc Pressure Distribution
Using elemental analysis, this session provides a complete end-to-end derivation of the horizontal/vertical equilibriums and differential equations of the historical work of Nadai, Von Karman and Orowan. Methods of calculating the circular arc pressure distribution, roll separating force and torque are presented. The classical methods of Bland and Ford, Bryant and Osborn, Roberts, and Stone are derived, along with a review of key roll bite sensitivities. 
11:30 a.m.Noncircular Arc Rolling Theories
The reality of the actual roll bite is discussed, along with the how, why and when the classical circular arc assumption is no longer valid. Slip/stick friction models are introduced and coupled with Hertzian roll flattening. The contemporary methods of Fleck and Johnson, Jortner, Alexander, Le and Sutcliffe are presented and reviewed. 
NoonLunch
1 p.m. Transverse Deflection and Characterization
Under force-loading conditions, the roll stack naturally deflects/bends over the strip across the transverse direction to form the geometry of the force-loaded roll gap/exit plane. The exit plane geometry defines the thickness profile of the exiting strip and therefore has a direct influence on the shape/flatness of the rolled strip. This session examines the underlying physics/contact mechanics that are involved, along with several methods of characterizing this geometry for use in shape/flatness evaluations and setup/pass scheduling modeling. 
2 p.m. Shape/Flatness – Physics of the Phenomena 
This session takes a deep dive into the fundamental, underlying physics of shape/flatness distortions. An illustrated analytic framework is introduced to provide a means of characterizing shape/flatness defects. Classical shape/flatness defects are reviewed and classified, along with how tension influences on-line/observed results. The analytic origin of the buckling threshold is presented, and a full derivation of the “I-Unit” designation is shown. 
3 p.m.Break
3:15 p.m.Shape/Flatness – Measurement Techniques
The physics of on-line shape measurement is presented, along with on-line/off-line flatness methods. Contemporary methods/systems are reviewed, along with a discussion on the fundamental limits of what can be understood from these measurements and how “phantom” defects are formed, along with the detrimental results. 
4 p.m. Shape/Flatness – Control and Targeting
After a quick review of multivariable control basics and system architectures, this session takes a deep look at the advanced analytical techniques applied to vertical stack and cluster/Sendzimir/20-high mills. A full review of orthogonal polynomials is undertaken, along with how they used to characterize both the shape error and the mill’s actuation. Various methods of control/actuation partitioning are presented, including how strip edges and partial edge zone conditions are handled.
5 p.m. End-of-Day Wrap-Up and Adjourn

Friday, 13 March 2026

7 a.m.Breakfast
8 a.m. Introductions and Opening Remarks
Brian Smith, ANDRITZ Metals USA Inc.
8:05 a.m.Automatic Gauge Control – Single-Stand Methods
The underlying analytical framework of automatic gauge control (AGC) is introduced and used to examine the classical single-stand modes of feedback, feedforward and mass flow, using roll gap, roll force, tension and speed actuation. On-line/active material adaption is also considered, with mode selection, activation and switching/spillover.
9 a.m. Automatic Gauge Control – Tandem Mill Methods
The various strategies of tandem mill gauge control are discussed in classical/typical mill arrangements.  The nature of the mass flow through the stands, tension-by-speed and tension-by-gap actuation are reviewed, along with noninteractive control strategies.  Methods associated with the application of gauge corrections and distributions are discussed, along with the consequences of specific stand loading and shape distortions.
10 a.m. Break
10:15 a.m.Tandem Mill Threading and Weld Passage
In this session, the sequential dance steps of closed-gap threading and tail-out are detailed and examined. Included is a discussion on the special case of thread-though/hot strip starting. Various methods of weld passage and flying gauge change will also be presented.
11:30 a.m.Performance Assessment
This brief session reviews the methods often used in the characterization of AGC and on-line shape control performance. The nature of thickness tolerances and on-line/off-line shape/flatness tolerances are also discussed.
NoonLunch
12:30 p.m. Pass Scheduling and Mill Set-Up
This session reviews various methods and strategies for scheduling sequential reduction plans and the associated setups for preparing the mill’s actuators and controls for rolling operations, based on mathematically predicted force-loading and conditions. The discussion will include handling the specific and distinct conditions of each rolling phase (sticking, threading, body rolling and tailing-out).
1:30 p.m. Special Topics and Open Forum Discussion
This closing session provides an open opportunity to talk about anything of interest: Material, process strategies, control systems, sensing/measurement, performance improvements/trade-offs, etc.  Everything is on the table.