Modelling of the Twin Roll Casting Process Including Friction

Twin roll casting is a combined solidification and deformation process and the material flow is thereby more complex than in many other casting processes. A modelling approach is presented including heat and fluid flow coupled with stresses and deformations. A Coulomb friction law is applied and by iterations on the mechanical conservation equations the parts of the cast surface that are either in slip or sticking mode against the roll shell are determined and tangential forces are calculated. Results like the total roll force and the forward slip on the strip are available from the model. Generally the model approach is applicable to both aluminium and magnesium casting with the appropriate material characteristics. In this study a 2D finite element simulation on the twin roll casting of a 1050 alloy is performed and the calculated roll force and forward slip are compared with results from industrial TRC processing trials.