Two-phase viscoplastic model for the simulation of twin roll casting

Rodrigues, Christian M. G.; Ludwig, Andreas; Wu, Menghuai; Kharicha, Abdellah; Vakhrushev, Alexander

doi:10.1016/j.jmatprotec.2020.116814

Cited by 18 publications

(7 citation statements)

References 13 publications

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“…Additional motivation of the present study is to verify a single-phase volume-averaging approach for the application to model a viscoplastic stress in the two-phase region during alloy solidification. On the contrary to the previously applied multiphase Eulerian-Eulerian volume-averaging model for the equiaxed crystal sedimentation [35][36][37] and the twin-roll casting process [38][39][40], the so-called mixture model is very robust, numerically stable and fast in sense of the calculation time required. As an advantage of the presented work, a full 3D model is considered including an SEN, a funnel-type thin slab mold (879 mm in height) and strand part (4000 mm along casting direction including mold).…”

Section: List Of Symbolsmentioning

confidence: 97%

“…Based on the previous experience of developing a numerical Eulerian-Eulerian model to simulate behavior of the packed bed of equiaxed crystals [35][36][37] and the macrosegregation during the twin roll casting [38][39][40], the viscoplastic stress model was applied to the thin slab casting by reducing it to the "mixture" formulation, which is more robust for the industrial scale simulations.…”

Section: Numerical Modelmentioning

confidence: 99%

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Norton-Hoff model for deformation of growing solid shell of thin slab casting in funnel-shape mold

Vakhrushev

Kharicha

et al. 2022

J. Iron Steel Res. Int.

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A funnel-type mold is commonly used to provide necessary clearance for the submerged entry nozzle in the thin slab casting (TSC). The partially solidified shell is subjected to the mechanical deformations, which can lead to the defects formation and, as a results, to a breakout. Traditionally, the results of the flow simulation, performed by the finite volume method (FVM), are fed to the external package for the finite element analysis of stress and strain. A coupled model was assembled using “creeping solid” approach by blending the Norton-Hoff viscoplastic stress for the solidifying shell with the Newtonian viscous stress of the liquid melt. The FVM was used to combine both liquid and solid stress models within a single solver. The iterative procedure based on the improved both side diffusion method was introduced to treat the nonlinear relation between the viscoplastic stress and the strain rate. The modeled shell thickness was verified by previously published breakout measurements and the simulation results. Temperature distribution, obtained during the TSC simulation, dominantly corresponds to the viscoplastic range. Developed numerical approach is robust and has direct industrial application.

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Section: List Of Symbolsmentioning

confidence: 97%

Section: Numerical Modelmentioning

confidence: 99%

Norton-Hoff model for deformation of growing solid shell of thin slab casting in funnel-shape mold

Vakhrushev

Kharicha

et al. 2022

J. Iron Steel Res. Int.

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“…It can be seen from the comparison in the figure that the simulation and the experiment show good consistency. To quantify the error between the experimental and numerical results, Root Mean Square Error (RMSE) [33] defined: (17) In the formula, Texp and Tsim are the outlet temperature values of the melt-pool obtained by experimental measurement and simulation calculation, respectively, and N is the number of test groups. According to the calculation of the equation, the TRMSE at the centerline of the melt-pool is 0.154, and the TRMSE at the exit surface of the melt-pool is 0.263.…”

Section: Experimental Verificationmentioning

confidence: 99%

“…They found that the casting temperature increase caused the rise of the strip temperature at the exit. Rodrigues et al [17] minimized the macrosegregation deviations in the strip and predicted an optimal strip quality in the TRC process. To increase the casting speed and expand the applicable range of alloys.…”

Section: Introductionmentioning

confidence: 99%

A Top Side-Pouring Twin-Roll Caster for 3.0 Wt.% Si Steel

Xuan

Zhang

Zhou

et al. 2021

Preprint

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Three-dimensional finite element modeling of twin-roll strip casting (TRC) and the top side-pouring twin-roll casting (TSTRC) were carried out to predict the temperature, flow, and turbulence kinetic energy of the two processes. The cellular automaton–finite element (CA-FE) model was established to predict the solidification structure of the two processes. By comparing the two processes, it was found that the temperature field distribution in the micro-melt pool during the TSTRC process was uniform. The temperature distribution in the width direction was also more uniform, and the stirring in the micro melt-pool was intense. An equiaxed crystal structure uniformly distributed in the width direction was obtained, and a thin strip of good quality was obtained. Not only the near-final forming of the thin strip was realized, but also the near-final forming of the solidified structure was realized. By comparing the experimental process of TSTRC with the simulation, it was found that the simulation and experimental results were in good agreement, which verified the feasibility and accuracy of the simulation.

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“…Several numerical models have been developed for the contact problem and air gap formation [20][21][22][23]. Deformation models coupled with the fluid flow, heat transfer, and solidification have been described elsewhere [24][25][26][27][28][29].…”

Section: Introductionmentioning

confidence: 99%

On Modelling Parasitic Solidification Due to Heat Loss at Submerged Entry Nozzle Region of Continuous Casting Mold

Vakhrushev

Kharicha

et al. 2021

Metals

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Continuous casting (CC) is one of the most important processes of steel production; it features a high production rate and close to the net shape. The quality improvement of final CC products is an important goal of scientific research. One of the defining issues of this goal is the stability of the casting process. The clogging of submerged entry nozzles (SENs) typically results in asymmetric mold flow, uneven solidification, meniscus fluctuations, and possible slag entrapment. Analyses of retained SENs have evidenced the solidification of entrapped melt inside clog material. The experimental study of these phenomena has significant difficulties that make numerical simulation a perfect investigation tool. In the present study, verified 2D simulations were performed with an advanced multi-material model based on a newly presented single mesh approach for the liquid and solid regions. Implemented as an in-house code using the OpenFOAM finite volume method libraries, it aggregated the liquid melt flow, solidification of the steel, and heat transfer through the refractory SENs, copper mold plates, and the slag layer, including its convection. The introduced novel technique dynamically couples the momentum at the steel/slag interface without complex multi-phase interface tracking. The following scenarios were studied: (i) SEN with proper fiber insulation, (ii) partial damage of SEN insulation, and (iii) complete damage of SEN insulation. A uniform 12 mm clog layer with 45% entrapped liquid steel was additionally considered. The simulations showed that parasitic solidification occurred inside an SEN bore with partially or completely absent insulation. SEN clogging was found to promote the solidification of the entrapped melt; without SEN insulation, it could overgrow the clogged region. The jet flow was shown to be accelerated due to the combined effect of the clogging and parasitic solidification; simultaneously, the superheat transport was impaired inside the mold cavity.

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Two-phase viscoplastic model for the simulation of twin roll casting

Cited by 18 publications

References 13 publications

Norton-Hoff model for deformation of growing solid shell of thin slab casting in funnel-shape mold

Norton-Hoff model for deformation of growing solid shell of thin slab casting in funnel-shape mold

A Top Side-Pouring Twin-Roll Caster for 3.0 Wt.% Si Steel

On Modelling Parasitic Solidification Due to Heat Loss at Submerged Entry Nozzle Region of Continuous Casting Mold

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