Optimum shape design techniques of direct roller under thermal load and rolling force in the direct rolling process of molten materials considering solid fraction

Abstract Rolling force in the direct rolling (or in the twin-roll strip continuous casting) process of semi-solid material has been computed using the rigid-viscoplastic finite-element method. Temperature distributions for calculations of rolling force and roll deformation are obtained from thermofluid analysis. Three-dimensional roll deformation analysis has also been performed using the commercial package ANSYS. From the results, the behavior of the metal flow, the rolling force and the roll deformation have been investigated according to the process conditions of semi-solid direct rolling.