Modelling of horizontal centrifugal casting of work roll

Abstract

A numerical model to simulate horizontal centrifugal roll castings is presented in this paper. In order to simulate the flow fluid and solidification of horizontal centrifugal roll casting correctly, the model uses a body fitted mesh technique to represent the geometry. This new method maps a plate layer mesh to a circular mesh. The smooth body fitted mesh method gives more accurate calculation results for cylindrical geometries. A velocity depending on the angular velocity and inner radius of the mould is set up as a velocity boundary condition. The fluid flow coupled with heat transfer and solidification in a rapidly rotating roll is simulated. A gravity free falling method is applied as a pouring condition. A moveable pouring system is also used in the simulations. High speed steel is used to produce the work roll. Two different gating positions and a moveable gating system are simulated in this paper. Results show that the position of pouring system has a significant influence on the temperature distribution. The temperature distribution at a fixed central pouring system is more favourable than the distribution from a side pouring system. A moving gating system method is a better way to obtain a uniform temperature field in centrifugal casting and offers an alternative for existing techniques. © Published under licence by IOP Publishing Ltd.