The process of producing thin strips of metal directly from the melt by twin roll casting (TRC) process pose severe challenges mainly associated with the solidification and shrinkage. The design of TRC allows completing the solidification before exit from the other end of the rolls. The process involves complex interactive phenomena such as heat transfer, fluid flow and solidification quite rapidly that is explicitly is a function of casting speed. In the current article, a steady-state coupled thermo-fluid model is developed following finite element method. The conservation of mass, momentum and energy including a standard k-ε turbulent model is considered in the symmetric solution domain. A new velocity and liquid sump height-dependent heat transfer coefficient confronted to the TRC process is proposed. The latent heat release during the process is accounted by employing the apparent heat capacity method. Darcy's porosity term is used to model the mushy zone. The numerical model is validated by comparing with experimental data from independent literature. The calibrated model is used to explicitly study the effect of casting speed on temperature distribution and cooling rate, liquid metal flow and mushy zone behavior. Overall, a comprehensive study on heat transfer and material flow is conducted to produce 1 mm thin aluminum strip produced by TRC process.