Our customer is one of the largest and leading manufacturer – exporters of products in its industry segment. It is engaged with production of alloy sheets through a process which involves rapid solidification and cooling of molten alloy over spinning wheel. The quality of 25µ sheet is directly dependent on its rate of cooling (> 1 million oC/s) which was targeted using coolant channel arrangement beneath the wheel. It was desired that the heat transfer process is numerically simulated and analyzed to improve the coolant channel design, and thereby, sheet quality.
Zeus Numerix developed a one dimensional transient heat transfer model to simulate solidification and cooling of molten alloy over the spinning wheel. The mathematical model was implemented in C++ and it allowed us to understand the effect of almost 15 process parameters on the cooling rate. CFD analysis of the coolant channel was also carried out to estimate heat transfer coefficient. Proprietary CFD package, CFDExpert-Lite™, was employed for the same. CFD analysis confirmed improvement of heat transfer by introducing baffles in channel.
Customer was delivered a detailed scientific analysis report that described that dependence of strip quality on the process parameters. The findings were confirmed by undertaking actual trails of strip casting. Moreover, the channel design was modified such that heat transfer coefficient increased by 150percentage. The exercise helped customer to substantially improve the quality of strip and achieve it consistently.