A thermal elastic-plastic finite-element analysis to roll-life prediction on the twin roll strip continuous casting proc
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INTRODUCTION
CURRENTLY, in strip production, the desired thickness of the strip is fabricated by the hot- and cold-rolling process, after the production of slab thicknesses of 200 to 250 mm by the conventional continuous casting process. This is particularly true in the production of thin strip, where conventional practice requires large thicknesses to be hot rolled into slabs and then into sheets before a final coldroll operation to the desired thickness. However, twinroll-type strip continuous casting processes are produced directly from the strip thicknesses ranging from 1 to 10 mm.[1–6] In recent years, much of the improvement in efficiency and in reduction of energy consumption in the steel industry has resulted from the application of strip continuous casting technology. These new processes, which include energy reduction, refining, and mainly near-net shape casting, must not only reduce costs, but also improve product quality. In spite of these advantages, the strip continuous casting process has many problems, such as the cooling roll design technology to improve the roll life. Roll-surface crack or thermal deformation can be greatly affected by the roll cooling system. The insufficient use of cooling water causes large thermal gradients in the vicinity of the roll surface, inducing thermal strain, which accelerates roll deformation. In addition, relatively high temperatures reduce the roll life, and create difficulties in obtaining the desired sheet thickness, thus deteriorating the surface finish as well as the metallurgical structures of the rolled sheets. As a consequence, the thermal behavior of the caster roll in the twin C.G. KANG, Associate Professor, Department of Precision and Mechanical Engineering, Engineering Research Center for Net Shape and Die Manufacturing, and Y.D. KIM, Researcher, Research Institute of Mechanical Technology, are with Pusan National University, Pusan, 609-735, Korea. Manuscript submitted October 25, 1995. METALLURGICAL AND MATERIALS TRANSACTIONS B
roll strip continuous casting process has always been of great concern to the roll designer or operator, especially in designing effective cooling systems to improve the roll life. In order to study the influence of cooling practices on the roll life, a good understanding of the thermal behavior of the caster roll is very important. In the twin roll strip continuous casting process, the reported results are limited to two-dimensional (2-D) solidification analysis considering fluid phenomena of molten metal. Kang and Kim[7] and Saitoh et al.[8] studied the roll deformation and solidification using an analytical approach and a finite-difference method, respectively. The reported modeling is limited to the temperature distribution of the casting alloy and the thermochemical properties as a function of roll temperature. As indicated in the aforementioned survey, a great many investigations have been done on the subject of the solidification analysis of the twin roll stripcasting process. However, a new mathematical model for th
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