Cast-rolling force model of multi-roll solid-liquid cast-rolling bonding process for fabricating metal cladding materials

Based on twin-roll casting technology and multi-roll groove rolling technology, a Multi-Roll Solid-Liquid Cast-Rolling Bonding (MRSLCRB) process was proposed to fabricate Cu/steel cladding bars, which processes the advantages of short flow and high-efficiency. However, it is a typical 3-D thermal-fluid-mechanics coupled problem, and determining cast-rolling force is difficult during the equipment design. Therefore, the geometrical evolution of the cast-rolling area was stud-ied, laying the foundation to establish contact boundary equations and analyze mechanical schematics and metal flow. Then, a 3-D steady-state thermal-fluid coupled simulation model, including casting roll, substrate bar, and cladding metal, was established. The Kissing Point (KP) height, average outlet temperature, and process window were predicted, and simulation results of the three-roll layout indicate that the KP distribution along the circumferential direction can be considered uniform. Hence, the engineering cast-rolling force model was derived based on the dif-ferential element method and plane deformation hypothesis. The accuracy was verified by the 3-D finite element model, and the influences of process layouts and technological parameters on the cast-rolling force were analyzed. Through the indirect multi-field coupled analysis method, the temper-ature-pressure evolution and reasonable process window can be predicted, which provides a signif-icant basis for guiding equipment design and improving product quality.(c) 2023 Production and hosting by Elsevier Ltd. on behalf of Chinese Society of Aeronautics and Astronautics. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/ licenses/by-nc-nd/4.0/).

Automated summary

This article proposes a Multi-Roll Solid-Liquid Cast-Rolling Bonding (MRSLCRB) process to fabricate Cu/steel cladding bars, using twin-roll casting technology and multi-roll groove rolling technology. The geometrical evolution of the cast-rolling area is studied to establish contact boundary equations and analyze mechanical schematics and metal flow. A 3-D thermal-fluid coupled simulation model is established to predict the Kissing Point (KP) height, average outlet temperature, and process window. The engineering cast-rolling force model is derived and verified, and the influence of process layouts and technological parameters on the cast-rolling force is analyzed. The temperature-pressure evolution and reasonable process window can be predicted, providing a significant basis for guiding equipment design and improving product quality.