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

本项目将开发和应用连铸过程中结晶器区域流体流动和热流的三维数学模型。该模型将在先前的二维有限元模型的基础上进行扩展，该模型包含湍流方程，并将喷嘴和模腔分开网格。这些模型将通过与内陆钢铁公司和ARMCO公司分别资助的连续板坯铸模的水模型进行的实验测量进行比较来验证。通过应用这些模型来研究单个工艺变量的影响，可以更好地理解缺陷形成的机制，并对钢板坯连铸工艺进行改进。本项目还将研究湍流流体流动及其伴随的传热数值计算的重要基本问题。这些包括网格细化、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当前数学流体流动建模的准确性，应用范围和最新技术。一旦开发出来，这些模型将扩展到其他铸造工艺，特别是薄板连铸机、单辊连铸机和双辊连铸机的“近净形”钢铸造工艺。这个项目将有助于设计这些新工艺，并可能对美国钢铁工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.