Control and Design of the Steel Continuous Casting Process Based on Advanced Numerical Models

Abstract

The process of continuous casting of steel is a complex technological task, including issues related to heat transfer, the steel solidification process, liquid metal flow and phase transitions in the solid state. This involves considerable difficulty in creating the optimal process control system, which would include the influence of all the physico‐chemical phenomena which may occur. In parallel, there is an intensive development of new mathematical models and an increase in computer performance, therefore complex numerical simulations requiring substantial computing time can be conducted. This paper presents a review of currently applied numerical methods allowing the phenomena accompanying the process of continuous casting of steel to be accurately represented. Special attention was paid to the selection of appropriate methods to solve the technological problem selected. The possibilities of applying selected numerical models were analysed in order to modify and improve the existing process or to design a new one linked to the implementation of new steel grades in the current production. The description of the method of defining the boundary conditions, initial conditions and material parameters as vital components ensuring that numerical calculations based upon them in the finite element method, which is that most frequently applied, are correct is an important element of the paper. The possibility of reliably defining the values of boundary parameters on the basis of information on the intensity of cooling in individual zones of the continuous casting machine was analysed.

Experimental determination of the shell thickness within the primary cooling zone in the continuous casting process

“…In the presented numerical model of the primary cooling zone, the boundary conditions may be implemented in three individual ways. The equation below describes the second-type (the Neuman condition) and the third-type of boundary conditions [17,18]: where T a is ambient temperature, K; σ is Stefan–Boltzmann radiation constant, 5.670373 × 10 −8 W m −2 K −4 .…”

“…The sensitivity analysis has shown that the correctness of numerical calculation results depends on the high accuracy and precision of material-related data implemented in the model [17]. From all the thermophysical parameters, the specific heat along with the latent heat is the most pivotal parameters.…”

“…From all the thermophysical parameters, the specific heat along with the latent heat is the most pivotal parameters. Enthalpy, at a set temperature, for metal alloys is defined as follows [17,18]: where c p is specific heat, kJ kg −1 K −1 ; L is latent heat, kJ; f S is solid fraction [0–1].…”

How electromagnetic stirring influences fluid flow in continuous casting of steel

“…This multiphysical nature in combination with a large scale of industrial casters makes this process challenging for computational modelling. The state of the art of continuous casting numerical simulation is summarized in [2][3][4]. Although much progress is made, accurate defect prediction is still in its beginning.…”

Modelling Microstructure in Casting of Steel via CALPHAD-Based ICME Approach

“…Numerical simulation of casting processes has been quite mature at the macroscopic level [9][10][11][12][13], including the finite difference method (FDM), finite element method (FEM) and finite volume method (FVM). Based on these methods, commercial simulation software [14] for the casting process have been developed, such as ProCast, Thercast, MAGMASoft, and Flow3D.…”