“…In the same manner as it has been realized in works [13][14][15][16][17][18] , the modeling has been provided by means of the FE software package ANSYS. Besides the already mentioned publications, this software has also been successfully used to simulate twin-roll casting of strips of aluminum and aluminum alloys 20 , various steels [21][22] and magnesium alloys 23 .…”
Section: Numerical Modeling Of the New Twin-roll Casting Methodsmentioning
The relatively high production costs of innovative materials with tailored properties such as Tailor Welded Blanks, Patchwork Blanks, Tailor Heat Treated Blanks and Tailor Rolled Blanks are responsible for a growing interest in new cost-effective production methods. One of the promising energy-saving and environmental friendly technologies for the production of tailored blanks is twin-roll casting. In the study a new alternative method for twin-roll casting of strips with profiled cross-section is proposed, which uses one or more preloaded endless steel strips with an antiadhesive coating for profiling of the formed strip on a pair of the common cylindrical shells. As a primary stage for the practical process design, numerical simulation of the process using the finite element software package ANSYS is realized. In this way, dependencies of the strip elements outlet temperature, deformation zone length and elements outlet speed on the varied strips thickness and total solidification-deformation zone length are established. Based on the simulation results, a procedure for the twin-roll casting process design is suggested.
“…In the same manner as it has been realized in works [13][14][15][16][17][18] , the modeling has been provided by means of the FE software package ANSYS. Besides the already mentioned publications, this software has also been successfully used to simulate twin-roll casting of strips of aluminum and aluminum alloys 20 , various steels [21][22] and magnesium alloys 23 .…”
Section: Numerical Modeling Of the New Twin-roll Casting Methodsmentioning
The relatively high production costs of innovative materials with tailored properties such as Tailor Welded Blanks, Patchwork Blanks, Tailor Heat Treated Blanks and Tailor Rolled Blanks are responsible for a growing interest in new cost-effective production methods. One of the promising energy-saving and environmental friendly technologies for the production of tailored blanks is twin-roll casting. In the study a new alternative method for twin-roll casting of strips with profiled cross-section is proposed, which uses one or more preloaded endless steel strips with an antiadhesive coating for profiling of the formed strip on a pair of the common cylindrical shells. As a primary stage for the practical process design, numerical simulation of the process using the finite element software package ANSYS is realized. In this way, dependencies of the strip elements outlet temperature, deformation zone length and elements outlet speed on the varied strips thickness and total solidification-deformation zone length are established. Based on the simulation results, a procedure for the twin-roll casting process design is suggested.
“…BC IV: The heat transfer coefficient remained constant. Its value was calculated by Equation (20). BC V: According to the surface temperature of the outlet strip, the averages of heat transfer coefficient of BC III was modified.…”
Section: Boundary Conditionsmentioning
confidence: 99%
“…After that, the solidified shells of each part on the roll surface are gradually connected into a whole. Under the action of cooling and contraction, the solidified shell in Figure 1(d) completely disengages from the roll surface [19,20]. Figure 1. Solidification of a molten metal on the surface of a matrix.…”
Twin-roll strip cast-rolling is a frontier process which produces a metallic strip directly from the melt. The main idea behind the presented research is to develop a new type of sectional roll surface heat transfer boundary condition. On this basis, a numerical simulation model of heat-flow coupling considering solidification was established to support the new boundary condition (BC). Finally, the simulation results are consistent with the experimental data, which verifies the BC. Meanwhile, the process parameters were optimized in depth through the model.
“…Gaps in Literature: Many researchers have modeled the solidification process in twin-roll casting [3][4][5][6][7] but few have considered the coupling between the thermal and mechanical dynamics [5,6]. In order to design a controller that achieves the desired performance objective of uniform strip thickness, we require a simple model that captures the relevant input-output dynamics of the process.…”
Section: Introductionmentioning
confidence: 99%
“…In order to design a controller that achieves the desired performance objective of uniform strip thickness, we require a simple model that captures the relevant input-output dynamics of the process. Santos et al [3] and Liu et al [4] created high-resolution simulations of the solidification process, but these are too complex to be used for control design. For example, Santos et.…”
We consider the problem of dynamic coupling between the rapid thermal solidification and mechanical compression of steel in twin-roll steel strip casting. In traditional steel casting, molten steel is first solidified into thick slabs and then compressed via a series of rollers to create thin sheets of steel. In twin-roll casting, these two processes are combined, thereby making control of the overall system significantly more challenging. Therefore, a simple and accurate model that characterizes these coupled dynamics is needed for model-based control of the system. We model the solidification process with explicit consideration for the mushy (semi-solid) region of steel by using a lumped parameter moving boundary approach. The moving boundaries are also used to estimate the size and composition of the region of steel that must be compressed to maintain a uniform strip thickness. A novelty of the proposed model is the use of a stiffening spring to characterize the stiffness of the resultant strip as a function of the relative amount of mushy and solid steel inside the compression region. In turn this model is used to determine the force required to carry out the compression. Simulation results demonstrate key features of the overall model.
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