Numerical Simulation of Filling Process During Twin-Roll Strip Casting
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nventional strip casting, the near-net-shaped twin-roll strip casting as can save around 70 pct of production and investment costs.[1,2] The twin-roll caster produces a thin strip through rapid solidification of molten steel as it feeds through a nozzle from a tundish into a wedge-shaped pool, composed of a couple of cooling rolls and two side-dams. The melt fed through the nozzle from tundish affects the flow patterns and the characteristics of heat transfer in the pool. The problems of twin-roll strip casting, such as break-out and ripple marks, associated with the transport phenomena in the pool can influence the stability of the casting process and the quality of strip.[1–6] Twin-roll strip casting is a very complicated process, in which turbulent flow, heat transfer, solidification, and plastic deformation can be completed in less than one second.[7–20] Over the past decade, several research efforts have been conducted to study the influence of the processing parameters and delivery system on the casting and rolling process. Tavares et al.[7,8] have developed a coupled turbulent fluid flow and solidification model for twin-roll strip casters and analyzed the effect of two kinds of simple metal delivery systems on flow patterns and solid shell formation. Hwang et al.[9,10] have simulated transient fluid flow, heat transfer, and ZHIYU LIU and QINGHUA ZHANG, Graduate Students, BO WANG and JIEYU ZHANG, Professors, and JIE MA, Ph.D. Candidate, are with the Shanghai Key laboratory of Modern Metallurgy and Materials Processing, School of Materials Science and Engineering, Shanghai University, Shanghai 200072, P.R. China. Contact e-mail: [email protected] Manuscript submitted July 10, 2013. Article published online January 8, 2014. 262—VOLUME 45B, FEBRUARY 2014
solidification behavior at the pouring stage of twin-roll strip casting. Wang et al.[11,12,20] have studied the molten steel transport characteristics and level fluctuations in the pool of twin-roll strip casting using the water model and mathematical simulations. In these reported research works, most studies are carried out with a 2D model for unsteady casting process. Only a few are studied with a 3D model and these have many simplifications, one of which is the use of a steady-state pool. However, more detailed information of flow pattern and surface profile must be gained using 3D unsteady numerical simulation method in the initial casting stage. It is very important for obtaining the optimal pool level and the formation of the solidified metal layer on the surface of twin-rolls during the filling process of twinroll strip casting. In this paper, the commercial software ProCAST was employed to simulate the 3D transient fluid flow, heat transfer, and solidifications behavior during the filling process of twin-roll strip casting process. The effect of three various delivery systems on temperature distribution and flow profile was studied in the initial stage of casting. The predicted results may provide more valuable information for understanding the filling process and optimizing deliver
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