The twin-roll casting process is simulated by a general thermomechanical model by using a versatile finite element method. The multidomain method is employed to deal with the solid and liquid phases separately. This includes treating the liquid phase as an Newtonian fluid and the solid phase as a viscoplastic metal. Furthermore, a friction model is proposed to analyze the rolling effect of the completely solidified metal. From the results of this study, the implementation of the friction model can produce a reasonable flow field of the solidified metal. In addition, the non-slip condition severely restricts the motion of the solidified metal and introduces inaccuracy on the temperature, velocity and stress fields as compared to the current approach.

Issue Section:
Research Papers
Topics:
Boundary-value problems, Casting, Finite element analysis, Friction, Simulation, Metals, Finite element methods, Flow (Dynamics), Fluids, Stress, Temperature, Thermomechanics
1.
Altan
T.
, and
Boulger
F. W.
,
1973
, “
Flow Stress of Metals and Its Application in Metal Forming Analyses
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
95
, pp.
1009
–
1019
.
2.
Chang
J. G.
, and
Weng
C. I.
,
1997
, “
Numerical Modelling of Twin-roll Casting by the Coupled Fluid Flow and Heat Transfer Model
,”
Int. J. Numer. Meth. Engr.
, Vol.
40
, pp.
493
–
509
.
3.
Chang
J. G.
, and
Weng
C. I.
,
1998
, “
Analysis of Flow and Heat Transfer in Twin-roll Strip Casting Process
,”
Int. J. Heat Mass Transfer
, Vol.
41
, pp.
475
–
487
.
4.
Engelman
M. S.
,
Sani
R. L.
, and
Gresho
P. M.
,
1982
a, “
The Implementation of Normal and/or Tangential Boundary Conditions in Finite Element Codes for Incompressible Fluid Flow
,”
Int. J. Numer. Meth. Engr.
, Vol.
2
, pp.
225
–
238
.
5.
Engelman
M. S.
,
Sani
R. L.
,
Gresho
P. M.
, and
Bercovier
M.
,
1982
b, “
Consistent vs. Reduced Integration Penalty Methods for Incompressible Media Using Several Old and New Elements
,”
Int. J. Numer. Meth. Fluids
, Vol.
2
, pp.
25
–
42
.
6.
Heinrich
J. C.
, and
Zienkiewicz
O. C.
,
1977
, “
Quadratic Finite Element Schemes for Two-Dimensional Convective Transport Problems
,”
Int. J. Numer. Meth. Engr.
, Vol.
11
, pp.
1831
–
1844
.
7.
Huebner, K. H., and Thornton, E. A., 1982, The Finite Element Method for Engineers, John Wiley & Sons, New York.
8.
Hwang
S. M.
, and
Kang
Y. H.
,
1995
, “
Analysis of Flow and Heat Transfer in Twin-roll Strip Casting by Finite Element Method
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
117
, pp.
304
–
315
.
9.
Hwang
J. D.
,
Lin
H. J.
,
Hwang
W. S.
, and
Hu
C. T.
,
1995
, “
Numerical Simulation of Metal Flow and Heat Transfer During Twin roll Strip Casting
,”
ISIJ Intern.
, Vol.
35
, pp.
170
–
177
.
10.
Karabin, M. E., and Smelser, R. E., 1985, “A Simplified Thermomechanical Model of Roll Casting,” paper 85-WA/HT-34 presented at ASME Winter Annual Meeting, pp. 17–21.
11.
Kim
S. W.
, and
Decker
R. A.
,
1989
, “
Velocity-pressure Integrated Verse Penalty Finite Element Methods for High-Reynolds-Number Flows
,”
Int. J. Numer. Meth. Fluids
, Vol.
9
, pp.
43
–
57
.
12.
Kobayashi, S., Oh, S., and Altan, T., 1989, Metal Forming and the Finite-Element Method, Oxford University Press, New York.
13.
Kroeger
P. G.
, and
Ostrach
S.
,
1974
, “
The Solution of a Two-dimensional Freezing Problem Including Convection Effects in the Liquid Region
,”
Int. J. Heat Mass Transfer
, Vol.
17
, pp.
1191
–
1207
.
14.
Miyazawa
K.
, and
Szekely
J.
,
1981
, “
A Mathematical Model of Splat Cooling Process Using the Twin-roll Technique
,”
Met. Trans. A
, Vol.
12
, pp.
1047
–
1057
.
15.
O’Malley
R. J.
,
Karabin
M. E.
, and
Smelser
R. E.
,
1994
, “
The Roll Casting Process: Numerical and Experimental Results
,”
J. Materials Processing & Manufacturing Science
, Vol.
3
, pp.
59
–
72
.
16.
Pelletier
D.
,
Fortin
A.
, and
Camarero
R.
,
1989
, “
Are FEM Solutions of Incompressible Flows Really Incompressible? (or How Simple Flows Can Cause Headaches!)
,”
Int. J. Numer. Meth. Fluids
, Vol.
9
, pp.
99
–
112
.
17.
Saitoh
T.
,
Hojo
H.
,
Yaguchi
H.
, and
Kang
C. G.
,
1989
, “
Two-dimensional Model for Twin-roll Casting
,”
Met. Trans. B
, Vol.
20
, pp.
381
–
390
.
18.
Shibuya
K.
, and
Ozawa
M.
,
1991
, “
Strip Casting Techniques for Steel
,”
ISIJ Intern.
, Vol.
31
, pp.
661
–
668
.
19.
Takuda
H.
,
Hatta
N.
,
Teramura
M.
, and
Kokado
J.
,
1990
, “
A Simple Model for Thermal Calculation in Twin-roll Strip Casting Process
,”
Steel Research
, Vol.
61
, pp.
312
–
317
.
This content is only available via PDF.
Copyright © 1999
 by The American Society of Mechanical Engineers
You do not currently have access to this content.