Numerical Simulation of Mold Filling and Solidification Process for Beam Blank Continuous Casting

2012 ◽  
Vol 538-541 ◽  
pp. 506-509
Author(s):  
Yan Juan Jin ◽  
Xiao Chao Cui ◽  
Zhu Zhang
Keyword(s):  
Velocity Field ◽  
Continuous Casting ◽  
Solidification Process ◽  
Mold Filling ◽  
Filling Process ◽  
Continuous Casting Mold ◽  
Commercial Code ◽  
Solidification Speed ◽  
Filling And Solidification

Mold filling and solidification of molten steel for 750mm×450mm×300mm continuous casting mold of single SEN and double SEN are simulated by using CFD commercial code Flow-3d. The distributing diagrams of velocity field and temperature field and the location and shape diagrams of free-surface during mold filling process are obtained. Influences of single SEN model and double SEN model on velocity field and solidification are analyzed. It is found that double SEN model can lighten circumfluence intensity at the upper of mold, quicken solidification speed of steel liquid in the mold, which is favorable to improving the quality of billet and enhancing pull speed.

Numerical Simulation of Filling and Solidification Process for Low Superheat Billet Continuous Casting

2011 ◽  
Vol 189-193 ◽  
pp. 3899-3903
Author(s):  
Yan Juan Jin ◽  
Xiao Chao Cui ◽  
Zhu Zhang ◽  
Jin Bao Lin ◽  
Jun Ting Zhang
Keyword(s):  
Continuous Casting ◽  
Liquid Steel ◽  
Solidification Rate ◽  
Submerged Entry Nozzle ◽  
Solidification Process ◽  
Billet Continuous Casting ◽  
Solidification Processes ◽  
Filling And Solidification ◽  
Low Superheat

In view of the process of flowing steel before the establishment of strip casting, the low superheat forced pouring continuous casting technology, i.e. the molten steel is cooled by the rotating cooling rollers, then it is forced to flow into mold, has been put forward in order to reduce superheat of liquid steel, enhance the efficiency of heat transfer and improve inner structure of billet. The filling and solidification processes of low superheat casting and submerged entry nozzle(SEN) casting are numerical simulated using fluid dynamics software. It is gained that velocity distributing diagrams, temperature distributing diagrams and solidification distribution diagrams at different time in the filling process. Influences of twin-roller cooling pouring on velocity field, temperature field and solidification are analyzed. The results show that the superheat of liquid steel is decreased and the solidification rate of liquid steel is increased by low superheat casting of twin-roller cooling process, which is favorable to improving the quality of billet and enhancing pull speed.

Effects of U-Shape Inner Cooler on Flow and Solidification of Molten Steel in Slab Continuous Casting Mold

2011 ◽  
Vol 291-294 ◽  
pp. 423-427
Author(s):  
Yan Juan Jin ◽  
Xiao Chao Cui ◽  
Zhu Zhang
Keyword(s):  
Fluid Dynamics ◽  
Temperature Field ◽  
Flow Field ◽  
Continuous Casting ◽  
Molten Steel ◽  
Continuous Casting Mold ◽  
Slab Continuous Casting ◽  
Cooling Technology ◽  
Steel Flow

An inner-outer coupled cooling technology of molten steel for 1240×200mm slab continuous casting, that is to set an inner cooler—U shape pipes in the mold, is put forward in order to enhance the efficiency of transmitting heat and improve inner structure of billet. The flow status and solidification status of molten steel under coupling flow field and temperature field in inner-outer coupled cooling mold are simulated by using fluid dynamics software, and compare with those in traditional mold. It is found that setting inner cooler in the mold can make molten steel flow status even, which is favorable to floating up of the inclusion, quickening the solidification of steel liquid and improving the quality of billet.

Conjugate Heat Transfer and Effects of Interfacial Heat Flux During the Solidification Process of Continuous Castings

2003 ◽  
Vol 125 (2) ◽  
pp. 339-348 ◽  
Author(s):  
M. Ruhul Amin ◽  
Nikhil L. Gawas
Keyword(s):  
Heat Transfer ◽  
Continuous Casting ◽  
Cooling Rate ◽  
Solidification Process ◽  
Air Gap ◽  
Gap Formation ◽  
Continuous Casting Mold ◽  
Withdrawal Velocity ◽  
Multiphase Fluid Flow ◽  
Multiphase Fluid

Multiphase fluid flow involving solidification is common in many industrial processes such as extrusion, continuous casting, drawing, etc. The present study concentrates on the study of air gap formation due to metal shrinkage on the interfacial heat transfer of a continuous casting mold. Enthalpy method was employed to model the solidification of continuously moving metal. The effect of basic process parameters mainly superheat, withdrawal velocity, mold cooling rate and the post mold cooling rate on the heat transfer was studied. The results of cases run with air gap formation were also compared with those without air gap formation to understand the phenomenon comprehensively. The current study shows that there exists a limiting value of Pe above which the effect of air gap formation on the overall heat transfer is negligible.

Numerical Simulation of Mold Filling and Solidification Process of a Disc Aluminum Alloy in Pressure Die Casting

2011 ◽  
Vol 121-126 ◽  
pp. 254-258
Author(s):  
Bai Yang Lou ◽  
Fang Li Liu ◽  
Kang Chun Luo
Keyword(s):  
Numerical Simulation ◽  
Mathematical Model ◽  
Aluminum Alloy ◽  
Die Casting ◽  
Solidification Process ◽  
Mold Filling ◽  
Casting Defects ◽  
Casting Simulation ◽  
Pressure Die Casting ◽  
Filling And Solidification

The numerical simulations of mold filling and solidification process for the A380 aluminum alloy were done by the supposed mathematical model. The casting defects in the process of mold filling and solidification were predicted by the result of the casting simulation. The casting defects of simulation are well compared with the practice. Some measures presented were improved for the existing technological process.

Numerical Simulation of Inclusion Capture in the Slab Continuous Casting Considering the Influence of the Primary Dendrite Arm Spacing

2018 ◽  
Vol 37 (4) ◽  
pp. 375-386
Author(s):  
Yanbin Yin ◽  
Jiongming Zhang ◽  
Shaowu Lei ◽  
Zhitong Wang
Keyword(s):  
Continuous Casting ◽  
Primary Dendrite ◽  
Three Dimensional ◽  
Solidification Process ◽  
Slab Surface ◽  
Continuous Casting Mold ◽  
Slab Continuous Casting ◽  
Dendrite Arm Spacing ◽  
Inclusion Concentration ◽  
Primary Dendrite Arm Spacing

AbstractIn the present work, a coupled three-dimensional numerical model of fluid flow, heat transfer, and inclusion motion during the solidification of molten steel in slab continuous casting mold has been developed. Based on the model, this paper has studied the inclusion capture during the process. The influence of the primary dendrite arm spacing on inclusion capture has been considered. The inclusion distributions, total masses, and average diameters at different depth from the slab surface have been given out in the present paper. The simulation results revealed the inclusion concentration existed in the solidification process, and the inclusion capturing area varies with the depth from the slab surface.

Numerical Study on Mold Filling Process of Casting

2008 ◽  
Vol 575-578 ◽  
pp. 87-92
Author(s):  
Xiao Qiang Pan ◽  
Hong Zhu Sun ◽  
Jun Da Chen ◽  
Yu Ling Zhu
Keyword(s):  
Numerical Simulation ◽  
Initial Conditions ◽  
Numerical Study ◽  
Solidification Process ◽  
Mold Filling ◽  
General Purpose ◽  
Filling Process ◽  
Numerical Heat Transfer ◽  
Multiphase Fluid Flow ◽  
Multiphase Fluid

Techniques of numerical simulation on mold filling process of casting are investigated in this paper. The mathematical model is formed on the ground of some selected theories in computational fluid dynamics (CFD), Numerical Heat Transfer (NHT) and computational methods to interfacial tracking. The discrete solution to the governing equations appeals to Finite Volume Method (FVM) on structured mesh. As for viscous turbulence flow and multiphase fluid flow in mold filling, engineering turbulence model and Volume of Fluid (VOF) method are adopted in the algorithms, respectively. As a debut, the general-purpose CFD software is used to establish the practicable mechanical model for the simulation. By means of numerical simulation, variation and distribution of velocity, temperature, stress and configuration of casting, etc. with respect to time and space in the filling process can be quantitatively analysed in detail, which is helpful for engineers to optimize their design of technics with less time and less cost and is meaningful to provide the subsequent simulation, solidification process of casting, with initial conditions.

Numerical Simulation of Chilled Cast Iron Camshaft in Sand Casting Process

2010 ◽  
Vol 44-47 ◽  
pp. 117-121
Author(s):  
Bin Feng He ◽  
Zhu Qing Zhao
Keyword(s):  
Numerical Simulation ◽  
Cast Iron ◽  
Solidification Process ◽  
Casting Process ◽  
Mold Filling ◽  
Sand Casting ◽  
Simulation Results ◽  
Improved Technology ◽  
Filling And Solidification ◽  
Chilled Cast Iron

There are many kinds of casting defects such as insufficient pouring, cooling separation, crack, and shrinkage and soon on were formed in the mold filling and the solidification process, which affect the final casting performance. Based on the mathematical models of mold filling and solidification process, the numerical simulation of chilled cast iron camshaft in sand casting process has been done. The filling behaviors at each stage in the filling process were presented. The temperature distributions in the solidification process were obtained, and the positions of shrinkages were predicted. According to the simulation results, an improved technology is proposed, and the shrinkages were eliminated efficiently. The simulation results are in good agreement with practical.

Numerical Simulation of Mold Filling and Solidification Behavior in Permanente Casting Process

2013 ◽  
Vol 313-314 ◽  
pp. 179-183
Author(s):  
Qing Ming Chang ◽  
Yin Kai Yang ◽  
Jing Yuan ◽  
Xia Chen
Keyword(s):  
Casting Process ◽  
Mold Filling ◽  
Permanent Mold ◽  
Gating System ◽  
Solidification Behavior ◽  
Mold Casting ◽  
Simulation Results ◽  
Permanent Mold Castings ◽  
Filling And Solidification

Melt flow and casting solidification are essential parts of the permanent mold casting process and affect significantly the quality of castings．For this reason, accurate prediction of mold filling pattern and temperature field in permanent mold castings plays on an important role in producing sound castings. In this paper, the model filling and solidification of a box casting produced from an aluminum alloy is studied. Different casting processes are employed, simulated and optimized to obtain sound castings. Simulation results reveal that with appropriate gating system, pouring rate, cooling line, a smooth mold filling, reduced shrinkages and other defects are available and desired sound castings can be produced.

Finite Element Analyses and Model of Squeeze Casting Process for Producing Magnesium Wheels

2012 ◽  
Vol 557-559 ◽  
pp. 2299-2302
Author(s):  
Chang Jiang Lin ◽  
Yin Jin ◽  
Hong Qing Tang
Keyword(s):  
Finite Element ◽  
Squeeze Casting ◽  
Solidification Process ◽  
Casting Process ◽  
Die Design ◽  
Finite Element Analyses ◽  
Alloy Wheel ◽  
Filling And Solidification ◽  
Squeeze Casting Process

A finite element equation has been developed to simulate the squeeze casting process of a magnesium alloy wheel, a parametric model has been established to confirm the temperature field during filling and solidification process. The model can be used to investigate the effects of die design and process parameters (die temperature, pressure etc.) on the quality of castings.

Simulation of Mold Filling and Solidification on Gravity Casting of Al-Si Alloy (A357)

2008 ◽  
Vol 575-578 ◽  
pp. 1204-1209
Author(s):  
Guo Fa Mi ◽  
Heng Tao Zhao ◽  
Kuang Fei Wang ◽  
Zhi An Xu ◽  
Ji Tai Niu
Keyword(s):  
Solidification Process ◽  
Mold Filling ◽  
Simulation Software ◽  
Temperature Fields ◽  
Al Alloy ◽  
Alloy Sample ◽  
Gravity Casting ◽  
Solidification Processes ◽  
Feeding Process ◽  
Filling And Solidification

The temperature at specific positions was measured by multi-channel data acquisition system in order to understand the solidification and feeding process of the sample. The Olympus metallurgical microscope was used to observe the macrostructure of the casting and analyze the freezing mechanism. The mold filling and solidification processes of the Al-alloy sample were studied by using the commercialized simulation software Z-Cast. And the simulated result was compared with the results of practical pouring test. When preheat temperature of mold is low, the pouring temperature should be higher in order to ensure completely filling of mold. As a result the solidification of sample could be feeding effectively, and the shrinkage on the upper end of sample could be eliminated. It is shown that the casting simulation software Z-CAST can be used to simulate the filling and solidification process of gravity cast Al alloy and can provide exact flow fields and temperature fields thus can predict cast defects and their positions.

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