Modelling and simulation of tilt-twin roll caster for 3003 aluminium alloy strip

Abstract

A 3-Dimensional model of the tilt twin roll caster was developed and used to produce quality AA3003 aluminium alloy strips. This twin roll caster has  thickness limitation because the quality of the aluminium alloy strip decreases when the strip thickness is below 7.2 mm. This developed model enables a  better understanding of casting speed, tip s`patial design, the setback, roll gap, degree of superheat and displacement of the tip for the production of  3003 Aluminium alloy strip. SOLIDWORKS Flow Simulation software was used for modelling and simulation while laboratory experiments were conducted  to validate model results. The model helps in the successful production of a 4.2 mm strip which is an improvement of over 40% compared to  strips previously been produced with the caster. The results also showed that for optimum performance of the Tilt-Twin Roll Caster, the setback should be  43 mm, the roll gap fixed at 3.5 mm, the tip orifice should be 3.8 mm, casting speed of 84 cm/min and casting temperature to be between 983 K and 993  K. In addition, the vorticity within the tip was observed to be directly related to the heat loss within the tip.