Effects of Magnetic Field on the As-Cast Structures of Dual-Ingot Low Frequency Electromagnetic Semi-Continuous Casting

2010 ◽  
Vol 97-101 ◽  
pp. 1033-1036
Author(s):  
Gao Song Wang ◽  
Zhi Hao Zhao ◽  
Jian Zhong Cui ◽  
Shuai Dong
Keyword(s):  
Magnetic Field ◽  
Continuous Casting ◽  
Three Dimensional ◽  
Low Frequency ◽  
Casting Process ◽  
Element Model ◽  
Magnetic Flux Density ◽  
Continuous Casting Process ◽  
Continuous Casting Mould ◽  
Three Dimensional Finite Element

Based on the non-uniform distribution of magnetic field within the ingot caused by its interactions during the dual-ingot low-frequency electromagnetic semi-continuous casting process, a three-dimensional finite element model was constructed. This model was meshed and calculated with the ANSYS software, and the distribution of magnetic field in low-frequency semi-continuous casting mould was obtained. The influence of the distance and current directions between two coils on magnetic field distribution in the ingot was studied. Calculated results showed that, during dual-ingot low-frequency electromagnetic semi-continuous casting process, whether the current was in the same direction or the reverse, magnetic field density on the remote end should be greater than that on the proximal of the same ingot; when the current directions of nearby coils were reverse, the magnetic intensity on ingot was higher than that with the same directions; as the distance between coils increased, the distal and proximal difference of magnetic flux density declined. Based on the results, a casting mould for dual-ingot electromagnetic semi-continuous casting ø152mm 7075 aluminum alloy was designed and produced. The experimental results showed that when the current directions of nearby coils were reverse, the as-cast macrostructures were a little bit better than that with the same directions. Moreover, when the current directions were reverse, the heterogeneity of the as-cast inner structure could be almost ignored.

3D Numerical Simulation of Electromagnetic Field during Low Frequency Electromagnetic Casting Process

2010 ◽  
Vol 154-155 ◽  
pp. 1472-1475
Author(s):  
Xiang Jie Wang ◽  
Jian Zhong Cui ◽  
Hai Tao Zhang
Keyword(s):  
Magnetic Field ◽  
Numerical Simulation ◽  
Three Dimensional ◽  
Low Frequency ◽  
Fem Analysis ◽  
Casting Process ◽  
Surface Region ◽  
Element Model ◽  
Current Intensity ◽  
Three Dimensional Finite Element

The rules of the distribution of magnetic field were carried out by numerical simulation. The distribution of magnetic field was got, and the effects of current intensity and frequency on the distribution of magnetic field were analyzed by constructing three-dimensional finite element model and using ANSYS software which is a kind of commercial FEM analysis software. The results show that the intensity of magnetic field is proportional to current intensity, magnetic field is mainly localized in the surface region of liquid melt and there is a notable edge effect in the corner.

3D Fem Study of Fluid Flow in the Mould for Billet Continuous Casting

2009 ◽  
Vol 79-82 ◽  
pp. 1269-1272
Author(s):  
Wei Chen ◽  
Bao Xiang Wang ◽  
Yu Zhu Zhang ◽  
Jin Hong Ma ◽  
Su Juan Yuan
Keyword(s):  
Fluid Flow ◽  
Continuous Casting ◽  
Casting Speed ◽  
Three Dimensional ◽  
Casting Process ◽  
Element Model ◽  
3D Fem ◽  
Billet Continuous Casting ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element

In this paper, a three-dimensional finite element model is developed to simulate and analyze the turbulent flow in the mould of billet continuous casting. The result shows that if the SEN is used in the continuous casting process, there exists a symmetrical stronger vortex in the middle of the mould and a weaker vortex above the nozzle. The casting speed, the depth and diameter of SEN all have significant effect on the fluid flow field and the turbulent kinetic energy on the meniscus, and then have effect on the billet quality. At the given conditions, the optimum set of parameters is: the casting speed 0.035 , the depth of the SEN 0.1 , the diameter of the SEN 0.025 . Online verifying of this model has been developed, which can be proved that it is very useful to control the steel quality and improve the productivity.

The Magnetic Field Interference in Dual-Ingot Low Frequency Electromagnetic Continuous Casting

2013 ◽  
Vol 821-822 ◽  
pp. 868-872
Author(s):  
Gao Song Wang ◽  
Zhi Hao Zhao ◽  
Jian Zhong Cui
Keyword(s):  
Magnetic Field ◽  
Continuous Casting ◽  
Low Frequency ◽  
Casting Process ◽  
Magnetic Flux Density ◽  
Current Direction ◽  
Continuous Casting Mold ◽  
Steel Sheets ◽  
Silicon Sheet ◽  
The Magnetic Field

The magnetic field interference was studied by numerical simulation and experimental examination during dual-ingot low-frequency electromagnetic casting process. By using ANSYS software package to mesh and compute, the magnetic field distribution of semi-continuous casting mold region was simulated. The calculated results were verified with the experimental ones and the effects of current direction, shield, silicon sheet and the coil distance on the distribution of magnetic field and ingot were observed. The result indicated that: regardless of current direction, the magnetic field interference among coils appears and the magnetic flux density weakens in the neighbor part of coils. When the current direction of adjacent coils is opposite, the magnetic intensity in ingots is stronger than that of in the same direction. As the distance between coils increases, the magnetic field reduction generated by interference decreases. The magnetic field interference can be alleviated by setting silicon steel sheets or shield.

Numerical Calculation About Influence of Crystallizer Structure on the Stress Evolution Process of Horizontal Continuous Casting of Copper Tubes

2021 ◽  
Author(s):  
Yao Xiao ◽  
Yi Han ◽  
Ming Huang ◽  
Xin-Liang Gao ◽  
Jia-Yin Liu
Keyword(s):  
Continuous Casting ◽  
Equivalent Stress ◽  
Semimajor Axis ◽  
Casting Process ◽  
Element Model ◽  
Cooling Zone ◽  
Continuous Casting Process ◽  
Horizontal Continuous Casting ◽  
Temperature Field Model ◽  
Measurement Experiment

Abstract The horizontal continuous casting plays a key role in the production of inner grooved copper tubes. In order to improve the accuracy of the temperature field model of the copper tubes horizontal continuous casting process, the model heat transfer coefficient was validated through temperature measurement experiment of graphite crystallizer. The finite element model of stress field evolution was established, based on considering the temperature and microstructure changes. It was found that tensile stress was generated in the outer layer of the casting billet and compressive stress was generated in the inner layer, when the casting billet entered the primary cooling zone. The paper investigated the mechanism of the liquid inlet number and shape on the microstructure and stress distribution after the casting billet was solidified. When the number of liquid inlets was 6, the ratio of the semimajor axis of ellipsoid to the short semi-axis was 3:2 and the backward tilt angle was 10°, the equivalent stress value of the casting billet was smaller and the grains were dense and uniform. This paper promotes the research of horizontal continuous casting process and provides measurable reference for improving the quality of casting billet in the further.

Modeling of the Steel Flow and Non-Metallic Inclusion Separation due to Flotation in a Six-Strand cc Tundish

2012 ◽  
Vol 706-709 ◽  
pp. 1556-1561
Author(s):  
Marek Warzecha
Keyword(s):  
Continuous Casting ◽  
Technological Development ◽  
Three Dimensional ◽  
Steel Production ◽  
Casting Process ◽  
Metallic Inclusion ◽  
Continuous Casting Process ◽  
Flow Through ◽  
Steel Flow ◽  
Physical Phenomena

Constantly increasing customers’ demands for the production of high and very high-quality steels, promote the intensive technological development of their production. Today, the dominating method of global steel production is continuous casting. A continuous casting plant includes the ladle turret, several steel ladles, a tundish, and a mold followed by a framework of rolls to support the strip. The tundish has become a very important metallurgical unit in the continuous casting process. Nowadays its role is not only to guaranty the link between the process of secondary metallurgy and the continuous casting process in the mould but it becomes an active metallurgical reactor. Therefore in recent years a lot of researches were done to establish a better understanding of the physical phenomena accompanying the steel flow through the tundish and non-metallic inclusion separation into the top slag cover. The article presents computational studies of the three-dimensional turbulent steel flow and non-metallic inclusions separation in a multi-strand tundish for steady-state casting conditions. Simulations of the steel flow in the tundish are performed with boundary conditions that are derived from the real casting process. The mathematical model used for simulations, was partly validated with experimental measurements. Numerical calculations are carried out by the finite-volume code Fluent using k-ε standard turbulence model. With the calculated flow field, micro-inclusions removal due to flotation to the coving slag is investigated numerically. For the particle separation at the interface a modified boundary condition is implemented.

Continuous Casting of a Multi-Crystalline Silicon Billet

2015 ◽  
Vol 833 ◽  
pp. 112-116 ◽  
Author(s):  
Mu Yi Li ◽  
Yan Hu ◽  
Hai Hao
Keyword(s):  
Heat Transfer ◽  
Continuous Casting ◽  
Production Efficiency ◽  
Crystalline Silicon ◽  
Three Dimensional ◽  
Element Model ◽  
Dimensional Finite Element ◽  
Lower Heat ◽  
Experimental Works ◽  
Three Dimensional Finite Element

In order to improve the production efficiency, numerical simulation and experiments of continuous casting of a multi-crystalline silicon (mc-silicon) billet were carried out. Modeling works were done firstly to optimize casting recipe and predict billet cooling behaviors, a three-dimensional finite element model for the simulation of thermal field and fluid flow was built. The continuous casting of cylindrical silicon billet was studied considering different casting parameters such as withdrawal speed and heat transfer ability of mold. The simulation results indicate that lower casting speed and lower heat transfer coefficient of mold are beneficial to acquire better morphology. Experimental works were practiced lying on the modeling results, using the self-designed mc-silicon continuous casting apparatus, mc-silicon billet with a diameter of 100 mm was obtained.

The Multi Physical Fields Modeling for 7B50 Aluminum Alloy Semi-Continuous Casting Process

2008 ◽  
Vol 575-578 ◽  
pp. 1422-1432
Author(s):  
Shi Cheng Hu ◽  
Wei Ce Ma ◽  
Xiao Qian Li ◽  
Jue Zhong
Keyword(s):  
Aluminum Alloy ◽  
Continuous Casting ◽  
Solid Phase ◽  
Thermal Contact ◽  
Convective Heat Transfer Coefficient ◽  
Three Dimensional ◽  
Solidification Process ◽  
Casting Process ◽  
Thermal Contact Conductance ◽  
Continuous Casting Process

In order to understand the solidification behavior in the semi-continuous casting process of 7B50 aluminum alloy, a thermo-mechanical model for the analysis of 7B50 aluminum alloy solidification process is presented, this model considering liquid-solid phase-change effects for the solidification alloy. The thermal contact conductance between the mould wall and the ingot, the convective heat transfer coefficient are taken into account in the model. The distribution of temperature and stress in the process of semi-continuous casting of 7B50aluminum alloy are analyzed in three-dimensional finite element methods based on the above models. The variation of casting speed to influence the temperature and stress of the ingot in the process of semi-continuous casting is studied.

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