• Transactions of the Korean Society of Mechanical Engineers B
• /
• v.23 no.1
• /
• pp.12-24
• /
• 1999

A computer program has been developed for analyzing the two-dimensional, unsteady conservation equations for transport phenomena in the molten region of twin-roll continuous casting in order to predict the turbulent velocity, temperature fields, and solidification process of the molten steel. The energy equation of the cooling roll is solved simultaneously with the conservation equations of molten steel in order to consider heat transfer through the cooling roll. The results show the velocity, temperature and solidification pattern in the molten region with roll temperature as a function of time. The results for velocity and temperature fields with solidification are compared with those without solidification, giving different thermofluid characteristics in the molten region. We also investigated the effects of revolutional speed of roll, superheat and nozzle geometry on the turbulent flow, temperature and solidification in the molten steel and temperature fields in the cooling roll.

• Transactions of the Korean Society of Mechanical Engineers B
• /
• v.25 no.3
• /
• pp.285-295
• /
• 2001

The transport phenomena in a wedge-shaped pool of twin-roll continuous caster are affected by the various operating parameters such as the melt-feed pattern, roll-gap thickness, melt-superheat, and casting speed. A computer program has been developed for analyzing the two-dimensional, steady conservation equations for transport phenomena during twin-roll continuous casting process in order to estimate the turbulent melt-flow, temperature fields, and solidification in the wedge-shaped pool. The turbulent characteristics of the melt-flow were considered using a low-Reynolds-number K-$\xi$ turbulence model. Based on the computer program, the effects of the different melt-feed patterns, roll-gap thicknesses, and superheats of melt on the variations of the velocity and temperature distributions, and the mushy solidification were examined. The results show that the liquidus line is located considerably at the upstream region, and in the lower region appear the well-mixed melt-flow and most widely developed mushy zone. Besides, the variation of melt-flow due to varying melt-feed patterns, affects mainly the liquidus line, and scarcely has effects on the solidus line in the outlet region.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.20 no.1
• /
• pp.189-205
• /
• 1996

The twin-roll type strip continuous casting process(or direct rolling process) of steel materials is characterized by two rotating water cooled rolls receiving a steady supply of molten metal which solidifies onto the rolls. A solidification analysis of molten metal considering phase transformation and thermofluid is performed using finite diffefence method with curvilinear coordinate to reduce computing time and molten region analysis with arbitrary shape. An enthalpy-specific heat method is used to determine the temperatures inthe roll and the steel. The temperature distribution of cooling roll is calculated using two dimensional finite element method, because of complex roll shape due to cooling hole in rolls and improvemnt accuracy of calculation result. The energy equaiton of cooling roll is solved simultanuously with the conservation equaiton of molten metal in order to consider heat transfer through the cooling roll. The calculated roll temperature is compared to experimental results and the heat transfer coefficient between cooling roll surface and rolling material(steel) is also determined from comparison of measured roll temperature and calculated temperature.

• Journal of the Korean Society for Precision Engineering
• /
• v.7 no.1
• /
• pp.37-52
• /
• 1990

In this study, the characteristics of cooling and rolling during strip casting process is obtained in comparison with the experimental and analytical results. The prupose of this study is to effectively analyze the thermal and mechanical deformation of roller applying the results of the heat transfer and the pressure distribution to boundary conditions. And then the relation between strip thickness and roll deformation is shown. The second purpose is to obtain the proper condition of the continuous casting for stainless steel. The summary and conclusions can be made on the basis of the results obtained by the theories and experiments. a) The strip casting condition for the fine surface quality of tin-alloy as-cast material was obtained in accordance with the velocity of roll rotation and initial roll gap. b) The experimental condition that the dimension of the cast strip thickness coincide with that of the initial roll gap was according to the experimental result of continuous casting by twin-roll type. c) The thermoelastic finite element model to calculate the roll deformation is represented. Thermoelastic model prediction for the roll deformation are in good agreement with the experimental results considering the thermal expansion of the roll. d) The higher cooling rates were obtained by a twin-roller quenching technique. Also quenched microstructure of the rapidly solidified shell was verified. e) The magnitude of roll deformation due to the thermal expansion and roll separating force is quantit- atively represented in the analysis of continuous casting for stainless steel.

• Corrosion Science and Technology
• /
• v.20 no.5
• /
• pp.315-323
• /
• 2021

In this study, we examined corrosion behaviors of two types of Pb alloys for a lead acid battery comparatively. One containing 6.6 wt% Sn, 36 mg/kg Bi, and 612.4 mg/kg Ca was prepared by twin-roll continuous casting. The other containing 5.2 wt% Sn, 30.5 mg/kg Ag, and 557 mg/kg Ca was made by twin-belt continuous casting. Potentiodynamic polarization tests were performed to evaluate corrosion resistance. Cyclic voltammetry was done to examine oxidation and reduction reactions occurring on the surface of each alloy in 4.8 M H₂SO₄ solution. Electrochemical test results implied that the Pb alloy prepared with the twin-belt casting method was less stable than that cast with the twin-roll method. Such results might be due to precipitations formed during the casting process. Rolling did not appear to affect the corrosion behavior of the twin-roll samples with Ag < 10 mg/kg, while it reduced the anodic reaction of Ag on the surface of the twin-belt sample with 30.5 mg/kg Ag.

• Transactions of the Korean Society of Mechanical Engineers
• /
• v.16 no.2
• /
• pp.400-408
• /
• 1992

In this paper, analysis of temperature and stress distributions in the roll for a twin roll continuous casting process was carried out. Firstly, several state equations were set up to determine the temperature distribution in the roll using finite difference method. Secondly, thermal stress in the roll was calculated numerically. Also, stress distribution due to the roll pressure was calculated to determine the effect of the roll pressure. For analysis of temperature distributions and the stress states of the roll, there are three kinds of roll materials, 2ICrMoV5. 11, CuCo/NiBe, CuCrZr and three types of cooling system were used.

• Transactions of Materials Processing
• /
• v.4 no.3
• /
• pp.233-244
• /
• 1995

Rolling force in the direct rolling(or twin-roll strip continuous casting) process fo semi-solid material has been computed using rigid-viscoplastic finite element method. Temperature distributions for calculations of rolling force and roll deformation are obtained from thermofluid analysis. Three dimensional roll deformation analysis has also been performed by using commercial package ANSYS. From the results, behavior of metal flow, rolling force and roll deformation have been investigated according to the process conditions of semi-solid direct rolling.

• Transactions of the Korean Society of Mechanical Engineers
• /
• v.11 no.6
• /
• pp.913-922
• /
• 1987

In this paper the solidification phenomena at the molten pool has been modeled and simulated in terms with the one dimensional unsteady-state heat transfer of the solid and molten phase and the pressure distribution in the solid phase for the twin-roller continuous casting of Sn-15% Pb. The further purpose of this study was to effectively analyze the thermal and mechanical deformation of roll applying the results of the heat transfer and the pressure distribution to the boundary conditions. The strip thickness of rapidly solidified metallic strip decreases with increasing angular velocity of the roller and with increasing initial roll gap. For this reason the roll spacing and angular velocity of the rolls are considered to be main variables. The recommended optimal casting regimes for continuous strip dimensions is near 0.8mm-1.0mm in thickness at the given angular velocity .omega.=2.0 rad/sec. Results of the experiment using Sn-15% Pb are compared with model predictions. The calculated roll deformation has been in good agreement with the observed value of roll deformatiion. All the deformation. All the deformation of the roller is within the elastic range, the plastic yielding are not occured. However, these elastic stresses are sufficient to take place of the shortened roller life by the thermal fatigue and a notch fatigue. The higher cooling rates were obtained by a twin-roller quenching technique. Also the quenched microstructure of the rapidly solidified shell was verified.

• Journal of the Korean Society for Precision Engineering
• /
• v.14 no.12
• /
• pp.73-85
• /
• 1997

The rolling force and roll deformation behavior in the twin roll type strip continuous casting process has been computed to estimate the thermal charcteristics of a caster roll. To calculation of rolling force, the relationship between flow stress and strain for a roll material and casting alloy are assumed as a function of strain-rate and temperature because mechanical properties of a casting materials depends on tempera- ture. The three dimensional thermal dlastic-plastic analysis of a cooling roll has also been carried out to obtain a roll stress and plastic strain distributions with the commercial finite element analysis package of ANSYS. Temperature fields data of caster roll which are provided by authors were used to estimated of roll deformation. Roll life considering thermal cycle is calculated by using thermal elastic-plastic analysis results. Roll life is proposed as a terms of a roll revolution in the caster roll with and without fine failure model on the roll surface. To obtain of plastic strain distributions of caster roll, thermomechan- ical properties of roll sleeve with a copper alloy is obtained by uniaxial tensile test for variation of temperature.

• Transactions of the Korean Society of Mechanical Engineers
• /
• v.18 no.4
• /
• pp.946-957
• /
• 1994

In the steel industries, direct rolling process for production of strip from molten metal has been investigated to simplify processes, to minimize energy consumption, and to improve quality of the strip. In this study, two kinds of practicable scale cooling rollers are proposed. And heat transfer analysis of pool region and cooling roller considering flow of molten metal and roll rotation respectively using the finite element method are performed to obtain the proper initial condition and to observe cooling characteristics of cooling roller. From the results, variations of solidification final points and temperature distribution in roller are observed quantitatively according to roll rotation.