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TECHNICAL PAPERS

Computer Modeling of Electromagnetic Fields and Fluid Flows for Edge Containment in Continuous Casting

[+] Author and Article Information
Fon-Chieh Chang

 Argonne National Laboratory, 9700 S. Cass Avenue, Argonne, IL 60439chang@anl.gov

John R. Hull

 Argonne National Laboratory, 9700 S. Cass Avenue, Argonne, IL 60439

J. Manuf. Sci. Eng 127(4), 724-730 (Dec 17, 2004) (7 pages) doi:10.1115/1.2039101 History: Received April 05, 2004; Revised December 17, 2004

A computer model was developed to predict eddy currents and fluid flows in molten steel. The model was verified by comparing predictions with experimental results of liquid-metal containment and fluid flow in electromagnetic (EM) edge dams (EMDs) designed at Inland Steel (Ispat Industries Ltd.) for twin-roll casting. This mathematical model can greatly shorten casting research on the use of EM fields for liquid metal containment and control. It can also optimize the existing casting processes and minimize expensive, time-consuming full-scale testing. The model was verified by comparing predictions with experimental results of liquid metal containment and fluid flow in EM edge dams designed at Inland Steel (Ispat Industries Ltd.) for twin-roll casting. Numerical simulation was performed by coupling a three-dimensional (3D) finite-element EM code (ELEKTRA) and a 3D finite-difference fluids code (CaPS-EM) to solve Maxwell’s equations, Ohm’s law, Navier-Stokes equations, and transport equations of turbulence flow in a casting process that uses EM fields. ELEKTRA is able to predict the eddy-current distribution and EM forces in complex geometry. CaPS-EM is capable of modeling fluid flows with free surfaces and dynamic rollers. The computed 3D magnetic fields and induced eddy currents in ELEKTRA are used as input to flow-field computations in CaPS-EM. Results of the numerical simulation compared well with measurements obtained from both static and dynamic tests.

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Copyright © 2005 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Configuration of conventional slab casting

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Figure 2

Configuration of twin-roll casting with ceramic solid dam

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Figure 3

Configuration of twin-roll casting with EMD

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Figure 4

Schematic representation of two-layer wall function model: (a) yp<yl and (b) yp>yl

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Figure 5

Schematic arrangement of EMD in twin-roll casting

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Figure 6

Horizontal magnetic flux density (Bx) as a function of vertical distance in air gap of EMD

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Figure 7

Distribution of magnetic flux density vector in a plane 15 cm above the nip of EMD in twin-roll casting

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Figure 8

Liquid metal (Indalloy) confinement for operating currents (a) I=13kA, f=4.4kHz and (b) I=18kA, f=4.4kHz

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Figure 9

Free surface of liquid AISI 304 in dynamic twin-roll casting with EMD

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Figure 10

Velocity profile of liquid AISI 304 in dynamic twin-roll casting with EMD

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