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Modeling of a continous casting process. Introduction. The purpose of this model is to describe the transition from melt to solid in the flow in the continous casting process.

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Modeling of a continous casting process


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Presentation Transcript
introduction
Introduction
  • The purpose of this model is to describe the transition from melt to solid in the flow in the continous casting process.
  • The COMSOL Multiphysics model results show the temperature distribution, the position of the solidification regime and the glow field in the melt within the process at steady state.
  • The model is a replica, with altered dimensions and material properties, of a real customer case. It was origially used to optimise the process.
problem definition
Problem Definition

outlet

  • 3D cylinder => 2D axi-symmetric model
  • Steady state model
  • Heat transfer including latent heat (solidification)
  • Flow field of melt with phase transition to solid including the ”mushy” region (i.e. where solid and liqud co-exist).
  • Temperature (and phase) dependent material properties

z

Air cooling

Water cooled

mould

Casting die

r

Melt inlet

heat transfer with latent heat
Heat Transfer With Latent Heat
  • Modified Heat equation:
  • Latent Heat as a Normalized Gaussian pulse around the melting temperature

with

  • Smoothing of thermal property functions using

COMSOL’s built in function: flc2hs

fluid flow with phase transition
Fluid Flow With Phase Transition
  • Reynolds number about 25 => Laminar flow
  • Navier-Stokes:
  • Damping at the solid/liquid interface:
  • Fraction solid phase:
results length of melted zone
Results, Length of Melted Zone

u=1.4 m/s

u= 2.3 m/s

u=1 m/s

  • Evaluating different casting rates (u).
  • =>Process optimization

Phase change

results melt flow
A vortex is present at the inlet, possibly explaining observed surface defects in the real process.

=> Optimization of die design

Results, Melt Flow

Recirculation

Zone

results heat flux
A majority of the heat is related to the phase transition.

The surface normal heat flux at the radial boundary shows how the cooling occurs.

=> Optimization of the cooling process

Results, Heat Flux

Conductive heat flux

Normal heat flux at boudary

conclusions
Conclusions
  • The model describes the casting process in terms of temperature, flow field and phase transition.
  • There is a significantly non-linear coupling between temperature and flow filed.
  • The model is relatively easy to set up and solve in COMSOL Multiphysics.