Abstract
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.
Highlights
Nowadays, the application of lightweight materials and optimized lightweight products is one of the promising ways of enhancements in different industrial branches such as transport, building or aerospace
The implementation of lightweight materials, for example for car body components, reduces the fuel consumption and, the amount of emitted pollutants. Another way to decrease the weight of constructions using common materials lies in their smart design: The properties of a part have to be inhomogeneous and fitted to the load path in response to applied forces. This approach has been already implemented in bulk production of sheet metal products for the automotive industry using different technologies such as application of Tailor Welded Blanks (TWB), Patchwork Blanks (PB), Tailor Heat Treated Blanks (THTB) and Tailor Rolled Blanks (TRB)[1,2]
The research results described above show that the numerical simulation of the twin-roll casting process in its different variants is a powerful tool for the determination of optimal process parameters, which can help to improve the interaction of the conditions between the shells and the processed metal and the quality of the strips as well
Summary
The application of lightweight materials and optimized lightweight products is one of the promising ways of enhancements in different industrial branches such as transport, building or aerospace. Stolbchenko et al, aided by the same software, carried out a theoretical study of the twin-roll casting parameters influence, such as melt temperature, casting rate, strip thickness and length of the solidification-deformation zone, on the plastic strain and temperature of a strip of an aluminum alloy EN AW6082 at the roll caster outlet[16]. The research results described above show that the numerical simulation of the twin-roll casting process in its different variants is a powerful tool for the determination of optimal process parameters, which can help to improve the interaction of the conditions between the shells and the processed metal and the quality of the strips as well. Getting an estimation of the optimal combination of parameters using FE-simulation of the new twin-roll casting process that allows manufacturing of strips with profiled cross-sections directly from the melt is the main goal of this study
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