Grozny State Oil Technical University named after Academician M. D. Millionshchikov, Grozny, Russia

N. D. Aysungurov, Associate Professor, Chair for Mechanical Engineering and Transport Processes, Candidate of Engineering Sciences, e-mail: aysungurov91@mail.ru
L. Kh.-A. Saipova, Associate Professor, Chair for Mechanical Engineering and Transport Processes, Candidate of Engineering Sciences, e-mail: saipova.lara@mail.ru
Kh. Kh. Aptaev, Senior Lecturer, Chair for Mechanical Engineering and Transport Processes, e-mail: halid.aptaev@mail.ru
M. A. Khadzhieva, Senior Lecturer, Chair for Mechanical Engineering and Transport Processes, e-mail: kafedratm2020@mail.ru

This paper examines the solution to the scientific and technical problem of producing sheet metal from high-strength heat-hardening aluminum alloys by direct casting and rolling, developing scientific and methodological approaches and practical recommendations for its implementation. A brief analysis of the status and development trends of modern industrial technologies used for sheet metal production is provided. It is shown that direct casting and rolling is one of the promising methods for producing sheet metal from high-strength aluminum alloys, allowing for the harmonized operation of all metallurgical units along the process chain and reducing associated energy and capital costs. The reason for the lack of a global technology for direct casting — rolling sheets from the materials under consideration — is explained. This lies in the very wide crystallization range (≥ 160 ^oC) of aluminum alloys of the Al – Cu and Al – Zn systems. It is noted that the difficulty of producing high-quality sheet blanks of a given thickness using roll casting is due to the fact that the formation of such blanks occurs instantaneously and is accompanied by an extremely complex interaction of heat and mass transfer processes. Therefore, these processes were studied using mathematical modeling in the ProCAST computer program. The initial data for the mathematical modeling included the geometric dimensions of the roll crystallizer (roll diameter and width), blank thickness, chemical compositions of the aluminum alloys under study, and their casting temperature and speed. Mathematical modeling of the processes of direct casting and rolling of the alloys made it possible to study the influence of heat and mass transfer processes in a two-roll crystallizer on the formation of sheet blanks thereof for different values of the main technological parameters of casting: linear casting speeds (0.3–1.2 m/s) and blank thicknesses (2–4 mm). As a result of computational experiments for all the studied aluminum alloys (B95, AMg5 and AD35), equations of the type V =f(Δt) were obtained for determining the main technological parameter of roll casting of metals — the linear casting speed for given technological process parameters: blank thickness (δ = 2–4 mm), metal meniscus angle (β = 10–33 deg.), roll radius (R = 200–400 mm); melt superheating temperatures (Δt = 10–60 ^oC). The obtained results provide a solid scientific basis for developing direct casting and rolling technology for a wide range of aluminum alloys, including high-strength alloys with a very wide crystallization range.

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