This paper presents a finite element approach for the analysis of the twin-roll strip casting process. Basic formulations for calculating the thermal and flow solutions are described, with emphasis on dealing with strong correlations between those solutions. Comparison with the experimental data found in the literature is made for examining the validity of the thermal solutions. A series of process simulations are carried out. The effect of various process variables on roll force, cooling rate,flow rate, and thickness of the solidified shell is investigated.
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