Simulation of electromagnetic field and its effect during electromagnetic stirring in continuous casting mold

Maurya, Ambrish; Kumar, Rohit; Jha, Pradeep Kumar

doi:10.1016/j.jmapro.2020.11.003

Cited by 53 publications

(28 citation statements)

References 40 publications

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“…To describe the liquid–solid transformation and formation of the mushy zone, a source term S h has been added to the energy conservation equation (Equation (17)). [ 20 ] S h is expressed as

S_{h} = ρ L \frac{\partial (1 - β)}{\partial t} + ρ L {bold-italicu}_{casting} \nabla (1 - β)

…”

Section: Model Descriptionsmentioning

confidence: 99%

“…In addition, mold electromagnetic stirring (M‐EMS) has been proven to be an effective method for altering the fluid flow and heat transfer behavior. [ 20–24 ] Most of these studies focused on the transient fluid flow in a billet mold based on the conventional casting speed. However, the fluid flow and heat transfer behavior at ultrahigh casting speeds exhibit obvious differences with conventional casting speeds that require further investigation.…”

Section: Introductionmentioning

confidence: 99%

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Numerical Simulation of the Fluid Flow, Heat Transfer, and Solidification in Ultrahigh Speed Continuous Casting Billet Mold

Zhang

et al. 2022

steel research int.

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Ultrahigh-speed casting is the most remarkable feature of billet high-efficiency continuous casting. The transient fluid flow, heat transfer, and solidification behavior under different casting speeds, submerged entry nozzle (SEN) parameters, and mold electromagnetic stirring (M-EMS) are investigated using a 3D transient mathematical model. The results show that a typical roll flow pattern is generated for all casting speeds, while a third small recirculation zone developed near the solidified shell at the casting speed of 6.0 m min À1 . When the casting speed increases, the impact depth of the molten steel increases from 0.748 to 0.844 m, the velocity and level fluctuation at the steel/slag interface increases, the high-temperature zone moves downward, and the shell thickness is reduced from 16.2 to 11.1 mm. As the SEN inner diameter and immersion depth increases, the impact depth increases, the velocity and level fluctuation at the steel/slag interface decreases, and the shell thickness at the mold exit is %11.0 mm. When the SEN immersion depth and inner diameter are 120 and 40 mm, respectively, the flow and temperature fields in the mold are the most appropriate. In addition, the M-EMS have a great effect on the fluid flow and heat transfer behavior.

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“…To describe the liquid–solid transformation and formation of the mushy zone, a source term S h has been added to the energy conservation equation (Equation (17)). [ 20 ] S h is expressed as

S_{h} = ρ L \frac{\partial (1 - β)}{\partial t} + ρ L {bold-italicu}_{casting} \nabla (1 - β)

…”

Section: Model Descriptionsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Numerical Simulation of the Fluid Flow, Heat Transfer, and Solidification in Ultrahigh Speed Continuous Casting Billet Mold

Zhang

et al. 2022

steel research int.

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“…Under the influence of EMS (I = 300 A), the streamlines and the resulting recirculation zones that appear below the SEN get modified because of the horizontal swirl flow of molten Vector as well as contours of the velocity is depicted at center plane of stirrer (Z = À0.3 m) for different casting speeds in Figure 7. The asymmetric flow patterns can be observed in Figure 7; it is because of the transient turbulent fluid flow model and also because of application of time variable MF for the EMS (Maurya et al, 2020). Moreover, it arises because of the presence of small eddies forming near the meniscus and the oscillating nature of the jet (Garcia-Hernandez et al, 2013;Liu and Li, 2018).…”

Section: Effect Of Casting Speed On Flow Behaviormentioning

confidence: 99%

“…As a result, coupling these models together will provide a better insight. Furthermore, under the effect of time-varying EMS (Maurya et al , 2020), the effect of casting speed on inclusion motion using a bifurcated SEN in the bloom mold has not been predicted. As a result, more research is needed to determine the impact of SEN design on inclusion motion behavior.…”

Section: Introductionmentioning

confidence: 99%

Effect of casting speed on solidification and inclusion motions in bloom mold caster under the influence of in-mold electromagnetic stirring

Kumar

Jha

2022

HFF

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Purpose The purpose of this article is to numerically investigate the effect of casting speed on the fluid flow, solidification and inclusion motion under the influence of electromagnetic stirring (EMS) in the bloom caster mold with bifurcated submerged entry nozzle (SEN). Design/methodology/approach The electromagnetic field obtained by solving Maxwell’s equation is coupled with the fluid flow, solidification and discrete phase model using the in-house user-defined functions. An enthalpy porosity approach and Lagrangian approach are applied for the solidification analysis and non-metallic inclusions motion tracking, respectively. Findings Investigation shows that the casting speed and EMS significantly affect the steel flow, solidification and inclusion behavior inside the mold. Investigations are being conducted into the complex interplay between the induced flow and the SEN’s inertial impinging jet. In low and medium casting speeds, the application of EMS significantly increases the inclusion removal rate. Inclusion removal is studied for its different size and density and further effect of EMS is also reported on cluster formation and distribution of inclusion in the domain. Practical implications The model may be used to optimize the process parameter (casting speed and EMS) to improve the casting quality of steel by removing the impurities. Originality/value The effect of casting speed on the solidification and inclusion behavior under the influence of time-varying EMS in bloom caster mold with bifurcated nozzle has not been investigated yet. The findings may assist the steelmakers in improving the casting quality.

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“…Many aspects of the continuous casting processes these days are being simulated using finite element method. It of course does not reflect fully the process, however, it may help to understand previously unknown variables such as temperature field [ 10 ], solidification [ 11 ] and solidification in the vacuum [ 12 , 13 ], fluid dynamics [ 14 ] or electromagnetic field and electromagnetic stirring [ 15 , 16 , 17 , 18 ]. The latter has been also extensively tested in the laboratory conditions and further on the industrial scale as electromagnetic stirring as it has been proven that it enables to improve the final product quality and the productivity of the process [ 19 , 20 ] and, what is more the as the authors in [ 21 ] claim the formerly inhomogeneous columnar grain structure turns into homogeneous equiaxed grain structure with the application of alternating magnetic field.…”

Section: Introductionmentioning

confidence: 99%

External Surface Quality of the Graphite Crystallizer as a Factor Influencing the Temperature of the Continuous Casting Process of ETP Grade Copper

et al. 2021

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Today’s world is a place where lack of electrical energy would be unimaginable for most of society. All the conductors in the world, both aluminum and copper, have their origin in various types of casting lines where the liquid metal after crystallization is being processed into the form of wires and microwires. However, the efficiency of the continuous casting processes of metals and the final quality of the manufactured product strictly depend on the design of the used crystallizers, the materials used during its production and its quality. Research conducted in this paper focuses on the latter, i.e., external surface quality of the graphite crystallizer at the place of contact with the primary cooling system. In order to quantify its influence on the continuous casting process numerical analyses using the finite element method has been conducted, which results have been further confirmed during empirical tests in laboratory conditions. It has been proven with all of the proposed methods that the temperature of the obtained cast rod is closely linked to the aforementioned surface quality, as when its roughness coefficient surpasses a certain value the temperature of the obtained product increases almost twofold from approx. 150–170 °C to 300–320 °C. These values might influence the quality and final properties of the cast rod, the susceptibility to wire drawing process and possible formation of wire drawing defects and therefore be of much importance to the casting and processing industry.

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Simulation of electromagnetic field and its effect during electromagnetic stirring in continuous casting mold

Cited by 53 publications

References 40 publications

Numerical Simulation of the Fluid Flow, Heat Transfer, and Solidification in Ultrahigh Speed Continuous Casting Billet Mold

Numerical Simulation of the Fluid Flow, Heat Transfer, and Solidification in Ultrahigh Speed Continuous Casting Billet Mold

Effect of casting speed on solidification and inclusion motions in bloom mold caster under the influence of in-mold electromagnetic stirring

External Surface Quality of the Graphite Crystallizer as a Factor Influencing the Temperature of the Continuous Casting Process of ETP Grade Copper

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