Physical Simulation of Sheet Billet Formation under Ingotless Metal Rolling

The physical simulation of sheet billet formation in the course of ingotless metal rolling has been performed. Parameters for controlling the processes of crystallization and the formation of the structure of such billets have been theoretically determined. The regularities of melt hydrodynamics in the interroll space and metal casting conditions of (overheating temperature, heat removal rate, etc.) affecting the mentioned processes have been established. By using a transparent organic alloy (camphene), an effect of heat-and-mass transfer processes in a roller mold exerted on the formation of the sheet billet structure in the course of ingotless metal rolling has been demonstrated. The transformation of the coarse primary structure of crusts solidifying on the rolls into a fine-grained structure (close to strained one) when the billet exits the rolling zone is clearly shown. An interrelation between the linear casting velocity of the model alloy and the overheating temperature of the melt and the heat removal rate from the mold rolls has been revealed. At the same time, specific values of parameters that guarantee the stability of the roll casting process are determined. Based on the obtained results, practical recommendations for the conditions of roll casting of real metals including steels have been proposed.