Research Initiation: Fluid Flow and Heat Flow Modeling of Continuous Casting Processes

本项目将开发和应用连铸结晶器区域内流体流动和热流的三维数学模型。这些模型将在以前开发二维有限元模型的基础上进行扩展，该模型结合了湍流方程，并为喷嘴和模具型腔划分了单独的网格。这些模型将通过与使用Inland Steel和Armco，Inc.的板坯连铸结晶器水模型进行的实验测量进行比较来验证，这两家公司的资金是分开的。通过应用这些模型来研究各个工艺变量的影响，可以更好地了解缺陷的形成机理，并对板坯连铸工艺进行改进。在这个项目中，还将研究湍流流动和伴随的换热的数值计算的基本问题。其中包括网格优化、收敛方案、湍流参数、边界条件以及两相流和浮力的结合。这项工作将有助于扩大目前数学流体流动建模的精度、应用范围和最新水平。一旦开发出来，这些模型将扩展到其他铸造工艺，特别是薄板坯连铸机、单辊和双辊连铸机的近净形铸钢工艺。该项目将有助于这些新工艺的设计，并可能对美国钢铁行业未来的竞争力产生巨大影响。

This project will develop and apply three dimensional mathematical models of fluid flow and heat flow in the mold region of continuous casting processes. The models will be extended from previous work developing two dimensional finite- element models, which incorporate the turbulence equations, and separate meshes for the nozzle and mold cavity. The models will be validated through comparisons with experimental measurements conducted using water models of continuous slab casting molds at Inland Steel and ARMCO, Inc., which are being funded separately. By applying these models to investigate the influence of individual process variables, the mechanisms of defect formation can be better understood and improvements made to the steel slab casting process. Fundamental issues important to the numerical calculation of turbulent fluid flow and the accompanying heat transfer will also be investigated in this project. These include mesh refinement, convergence schemes, turbulence parameters, boundary conditions, and incorporation of two-phase flow and buoyancy. This work will help extend the current accuracy, range of application and state-of-the-art of mathematical fluid flow modeling. Once developed, the models will be extended to other casting processes, particularly the "near-net-shape" steel casting processes of continuous thin-slab, single-, and twin-roll casters. This project will help in the design of these new processes, and could have a tremendous impact on the future competitiveness of the American steel industry.