Numerical Modelling of Twin-Roll Casting by the Coupled Fluid Flow and Heat Transfer Model

Abstract

SUMMARYThe twin-roll process is modelled by a coupled fluid flow and phase change model by means of a versatile finite element method. Here, a simple numerical scheme is proposed to solve the problem of determining the interface shape under the thermal equilibrium condition. The procedure is based on a finite element method using a transform technique. The simple numerical method provides an efficient and accurate way to find the interface position and shape with arbitrary boundary geometry. This method can easily be implemented on the existing finite element program, and provides a simple and efficient tool to simulate the solidification as well as the fluid flow problem of the twin-roll casting process.

Modelling of twin‐roll strip casting processes

“…References [1][2][3][4][5][6][7] and references therein). In particular, the analysis of twin-roll strip casting processes requires the solution of thermal and ow patterns where the phasechange front position is an important operation variable that a ects, among others, the quality of the ÿnal product [7][8][9][10][11][12][13][14][15][16][17][18][19]. It is a well-known fact that this process can be considered as the combination of two major conventional industrial procedures: continuous casting and hot rolling.…”

“…The integration of such processes o ers further savings in energy and manufacturing costs, produces better properties in the ÿnal product due to the high cooling rates but, however, needs more complex control systems. Moreover, increasing roll speeds are required in order to improve the production although, as widely reported, it may induce some casting defects and operational di culties [7][8][9][10][11][12][13][14][15][16][17][18][19]. From the numerical point of view, two di erent analyses can be distinguished in the simulation of twin-roll casting processes: purely thermal [8,9,18,19] and thermally coupled ow [10][11][12][13][14][15][16][17] approaches.…”

“…On the other hand, the second approach involves the coupled analysis of both the ow and thermal problems described by the full Navier-Stokes equations. In this last framework, the phase-change e ect has been taken into account by means of a transforming-grid ÿnite element formulation [10,11], a temperature recovery ÿnite element method [12], a ÿxed-mesh e ective capacity ÿnite volume algorithm [13,14] and an enthalpy-porosity ÿnite volume technique [15][16][17]. Moreover, turbulent uid ow for the liquid and mushy phases as well as viscoplastic e ects for the solid and mushy regions due to the high temperatures involved have been usually considered in the modelling of this process.…”

Modeling of Fluid Flow and Heat Transfer in Twin-Roll Casting of Aluminum Alloys

“…Various mathematical models [2][3][4][5][6][7] have been suggested in the literature to predict the fluid flow, heat transfer, and solidification in twin-roll casters. Most of the papers deal with fluid flow modeling in vertical twin-roll casters, but only a few papers 6,7) deal with the fluid flow modeling in horizontal twin-roll casters.…”

“…Most of the papers deal with fluid flow modeling in vertical twin-roll casters, but only a few papers 6,7) deal with the fluid flow modeling in horizontal twin-roll casters. Miyazawa and Szekely 2) were the first * 1 Graduate Student, The Ohio State University.…”