Process parameters and roll separation force in horizontal twin roll casting of aluminum alloys

A two-dimensional finite element analysis was carried out to predict roll separation force, temperature distribution, and the shape of the mushy zone during horizontal twin roll casting of A7075 aluminum strips. Various effect of roll speeds and initial temperatures of the melt on casting was considered. Modeling twin roll casting focused on roll separation force had merits of predicting mechanical interaction between the rolls and solid strips, in addition to temperature distribution. The roll speed has a great effect on roll separation force, compared with heat transfer coefficient and melt temperature. The predicted roll separation force was compared with the measured one during twin roll casting. The results can be used effectively to reduce the experimental trial-and-error procedures of twin roll casting process.