Numerical Simulation of Cast-rolling Process for Copper-Aluminum Composite Plate

Taking horizontal twin-roll casting mill as the research object, the geometric modeling and gridding of the rolling mill are completed by using the design modeler and gridding module of ANSYS Wrkbench platform. Combined with Fluent fluid simulation module, a two-dimensional steady-state laminar flow coupled model of copper-aluminium clad plate cast-rolling process was established. Through the analysis of range data obtained by orthogonal simulation design method, the order of importance of each factor is as follows: billet speed, cast-rolling zone length, preheating temperature of copper strip, pouring temperature. Through the analysis of factors and indicators (liquid hole depth ratio), the suitable technological parameters range are 0.3~0.6 m.min-1 for billet speed, 933~993 K for pouring temperature, 300~431 K for preheating temperature of copper strip, 57~80 mm for cast-rolling zone length. In order to verify the reliability of numerical simulation method and result analysis, the casting-rolling test was carried out with simulated process parameters. The exit temperature was measured by thermocouple. The results show that the error between simulation results and measured results is small, which verifies the accuracy of simulation and the feasibility of guiding production. When the billet speed is 0.5 m/min, the pouring temperature is 963 K, the length of casting-rolling zone is 70 mm and the copper strip is not preheated, the 10 mm thick copper-aluminium composite plate has better shape. The tensile properties show that the composite plate has both the high plasticity of aluminium and the high strength of copper.