Effect of electromagnetic stirring on flow field in mold under submerged entry nozzle clogging

A physical model with mercury as analog was developed to investigate the influences of electromagnetic stirring( EMS) on flow field in slab continuous casting when the submerged entry nozzle( SEN) was clogged with different clogging rates( 0,10%,25%,and 50%). The flow field in mold under different EMS currents( 0,40 A,and 60 A) was measured by an ultrasonic Doppler velocimeter. The results proved that the flow field in the mold was a typical double roll structure under non-clogging SEN. As the SEN clogging rate increased,the flow field structure was transformed from a double roll to asymmetry flow. When the clogging rate reached 50%,the up circulation disappeared on the clogged side. The zone under the meniscus near the narrow face was a non-flowing area. EMS could correct bias flowcaused by SEN clogging and improve the symmetry of the flow field during SEN clogging.     

Numerical Simulation of Electromagnetic Field and Flow Pattern in a Continuous Slab Caster with In-roll Type Strand Electromagnetic Stirring

The electromagnetic field and flow analysis model were developed to simulate the electromagnetic field and the flow pattern in a vertical curved continuous slab caster with the in-roll type strand electromagnetic stirring.The transient electromagnetic field distribution and the induced electromagnetic force were numerically described.The effects of stirring current,stirring frequency,and different stirrer configurations on the electromagnetically driven flow field in the strand were investigated and the optimization of the stirring parameters was discussed by performing a relative comparison of numerical results.Results show that the in-roller type strand electromagnetic stirrer(SEMS)pair generates the fluctuating magnetic fields,penetrating through the cast slab and periodically parallel shifting along the slab wide face with time evolution.The transient induced electromagnetic forces travels toward the magnetic flux shifting direction.Different stirring parameters(i.e.current and frequency)and stirrer configurations affect the stirring strength and the flow recirculation pattern in the strand,which are closely related to metallurgical performances of the stirrers.There is an optimum frequency to obtain the maximum stirring.The present model provides a relatively theoretical insight into the in-roll type strand electromagnetic stirring system for best operating.     

电磁搅拌对特大方坯结晶器内流场及温度场影响

以某厂断面为410 mm × 530 mm的特大方坯结晶器为原型,利用ANSYS有限元软件建立三维数值模型,研究电磁搅拌对结晶器流场及温度场的影响。施加电磁搅拌后,钢液受到径向电磁力,液面呈现旋转流动趋势。结晶器内钢液最大切向速度随着电流的增加而增大,随着频率的增加而减小。电磁搅拌的电流大小由0 增加到500 A时,液面波动由1.21 mm增加到4.35 mm。电磁搅拌能够使钢水的高温区局限于连铸结晶器上部,钢水温度更加均匀。同时钢液的水平旋流能够抑制初生坯壳的生长,降低坯壳的生长速度,使结晶器出口处坯壳厚度变薄。综合分析,该厂在实际生产时合理的电磁搅拌的电流大小应为400 A,频率为1.5 Hz,此时钢渣液面波动约为2.73 mm,温度场较为均匀。      

薄板坯二冷区电磁搅拌铸坯内磁场分布和钢液流动

针对特定设计的搅拌器建立了包含钢液流动、传热和电磁场的三维耦合非稳态数学模型,计算了CSP薄板坯二冷区液芯在电磁搅拌作用下的传输行为,其中考虑了感应电流和搅拌器线圈上下端部对磁场强度的影响.结果表明:电磁力改变了铸坯液相穴内钢液流场,对钢液起到水平搅拌作用;搅拌器产生的磁场不均匀,在不同厚度处幅度和相位都不同,且幅度随着穿透深度的增加而减小;感应磁场移动方向与外部磁场相同且不宜忽略;单侧搅拌器对铸坯内钢液搅拌比较均匀.      

Simulation on Effect of Divergent Angle of Submerged Entry Nozzle on Flow and Temperature Fields in Round Billet Mold in Electromagnetic Swirling Continuous Casting Process简

A new process for swirling flow generation in the submerged entry nozzle （SEN） in continuous casting process of steel was proposed. A rotating electromagnetic field was set up around the SEN to induce swirling flow by Lorentz force. The flow and temperature fields in the SEN and round billet mold with electromagnetic swirling were numerically simulated and then verified by the electromagnetic swirling model experiment of low melting point alloy. The effects of divergent angle of the SEN on the flow and temperature fields in mold with electromagnetic swirling were investigated. The electromagnetic swirling flow generator （EMSFG） could effectively induce swirling flow of molten steel in the SEN, which consequently improved greatly the flow and temperature fields in the mold. Below the nozzle outlet in mold, with the increase of divergent angle, the stream of bulk flow diverged more widely, the high temperature zone shifted up, and the temperature field became more uniform. Above the nozzle outlet in mold, with 350 A electromagnetic swirling, when the divergent angle of the SEN increased, the upward flow velocity and the meniscus temperature first increased and then decreased. With a divergent angle of 60~, the upward flow velocity and meniscus temperature reaced the largest value.     

圆坯凝固末端电磁搅拌作用下的流动与传热行为

以特殊钢圆坯连铸为研究对象, 建立了研究凝固末端电磁搅拌作用效果的三维耦合数值模型.利用分段计算模型获得末端电磁搅拌区域钢液流动与凝固的实际状态, 并采用达西源项法处理凝固末端钢液在糊状区的流动, 研究了不同电磁搅拌工艺参数下的电磁场分布及钢液的流动与传热特征.通过测量搅拌器中心线磁感应强度和铸坯表面温度验证了模型的准确性.研究结果表明: 电流强度每增加100 A, 搅拌器中心磁感应强度增加19.05 mT, 电磁力随着电流强度的增加显著增大.在20~40 Hz范围, 随着电流频率的提高, 中心磁感应强度略微下降, 但电磁力仍有所增加.在搅拌器区域, 液相穴内的钢液在切向电磁力的作用下旋转流动, 其切向速度随着电流强度和频率的增加而变大.末端电磁搅拌可促进钢液在圆坯径向的换热, 随着电流强度和频率的提高, 铸坯中心轴线上的钢液温度降低, 同时末端搅拌位置处的中心固相分率增加.      

Numerical Modeling of Inclusion Removal in Electromagnetic Stirred Steel Billets

To investigate the inclusion removal in billets cast under electromagnetic stirring (EMS) influence, a numerical model has been developed to compute the magnetic field, the Lorentz force, the steel flow velocities, and the particle transport within the liquid pool. The electromagnetic field was described by the Maxwell equations and the finite element method was applied using a commercial package. The turbulent fluid flow was described by the Navier‐Stokes equation and by the Reynolds Stress model and the finite volume method was applied using another numerical package. The time average of the Lorentz force was calculated in each element center and this value was applied as a body force in the Navier‐Stokes equation. The magnetic flux density profile was compared with the data obtained in the stirrer of the steel plant. The particle transport model includes the drag force, the buoyancy force and the random walk model, to include the turbulence effects on the particle trajectory. The inclusion removal was calculated and analysed in function of casting speed and stirring current for one size section of mold. The inclusions considered in the calculations have a fixed density and four values of diameter. The numerical results of the electromagnetic model are in agreement with the experimental measurements. A good relationship between the electromagnetic model and the fluid flow model could be shown. An interesting effect is the break of the rotation motion due to the EMS by the jet from the nozzle. The fraction of inclusions removed by the top surface of the mold was improved due to the EMS.     

电磁搅拌对大圆坯结晶器冶金行为影响的探讨

 为了探究结晶器电磁搅拌(M EMS)对大圆坯结晶器内综合冶金行为的影响。以大断面圆坯连铸结晶器冶金行为为研究对象，基于电磁热流体与凝固传输理论建立三维耦合数值模型。揭示大圆坯连铸常用五孔水口浇注条件下结晶器内电磁场、流场、传热与凝固等综合冶金行为，提出电磁搅拌对结晶器冶金性能影响的多参量评价方法。以中碳铬钼齿轮钢650 mm大圆坯连铸为例，指出结晶器电磁搅拌存在最佳搅拌电流，可获得相对较好的综合冶金效果。具体表现为弯月面保持一定的切向速度和过热度，有利于保护渣的熔化和夹杂物的上浮去除；液面波动幅度在控制范围内，可避免卷渣、改善表面质量；结晶器内钢液过热得到有效耗散，有利于等轴晶形核改善铸坯内部质量；侧孔出流钢液速度得到有效控制，可抑制注流对初凝坯壳的冲刷，提高了初生坯壳生长的均匀性。此外，电磁搅拌产生的水平旋流强度也可得到有效控制，有利于避免常见的皮下白亮带现象。     

连铸结晶器电磁搅拌磁场及钢液流场模拟

 建立了大方坯连铸结晶器电磁搅拌条件下电磁场及钢液流场数学模型,开发了相应的Visual Cast仿真软件,并应用软件模拟分析了大方坯连铸结晶器内磁场、电磁力分布及双侧孔浸入式水口条件下结晶器内钢液流场的分布特征。结果表明,结晶器内磁场分布均匀,并沿横断面水平旋转,电磁力的旋转周期为磁场旋转周期的一半。电磁搅拌改变了结晶器内流场形态,减小回流区和冲击深度,有利于促进钢液中非金属夹杂物上浮排除,提高大方坯洁净度。     

Effect of mold EMS design on billet casting productivity and product quality

Increased casting productivity, especially with the introduction of high speed billet casting (HSBC), re-emphasized the importance of high performing mold electromagnetic stirring (M-EMS) in attaining the targets of productivity and product quality. To provide operating flexibility and to enhance metallurgical performance, adapting M-EMS design to the requirements of casting practice with either the open stream pouring or submerged entry nozzle (SEN) has become critical. In that context, it is especially important to assess the effects of EMS design parameters that control stirring velocity in the meniscus region and the rest of the mold. Such a control is the key to EMS compatibility with the continuous casting practice and its high metallurgical performance.In this paper, we discuss different M-EMS designs with reference to their metallurgical performance.     

Structure of turbulent flow in a slab mold

The structure of the turbulent flow in a slab mold is studied using a water model, various experimental techniques, and mathematical simulations. The meniscus stability depends on the turbulence structure of the flow in the mold; mathematical simulations using the k-ε model and the Reynolds-stress model (RSM) indicate that the latter is better at predicting the meniscus profile for a given casting speed. Reynolds stresses and flow vorticity measured through the particle-image velocimetry (PIV) technique are very close to those predicted by the RSM model, and maximum and minimum values across the jet diameter are reported. The backflow in the upper side of the submerged entry nozzle (SEN) port (for a fixed SEN design) depends on the casting speed and disappears, increasing this process parameter. At low casting speeds, the jet does not report enough dissipation of energy, so the upper flow roll is able to reach the SEN port. At high casting speeds, the jet energy is strongly dissipated inside the SEN port, the narrow wall, and in the mold corner, weakening the momentum transfer of the upper flow roll, which is unable to reach the SEN port. At low casting speeds, meniscus instability is observed very close to the SEN, while at high casting speeds, this instability is observed in the mold corner. An optimum casting speed is reported where complete meniscus stability was observed. The flow structure at the free surface indicates a composite structure of islands with large gradients of velocity at high casting speeds. These velocity gradients are responsible for the meniscus instability.     

结晶器电磁搅拌对圆坯质量影响的研究

通过数值模拟计算了马钢圆坯连铸（断面尺寸为Ф450mm）电磁搅拌参数对磁场分布的影响,并通过生产试验研究了电磁搅拌参数对铸坯质量的影响。模拟计算表明,结晶器磁场强度随着搅拌电流的增加而增大,电流不变时,频率越小,磁场强度越大。现场试验表明,采用电磁搅拌能有效改善铸坯低倍组织,搅拌电流越大,铸坯中心等轴晶比率越高;电磁搅拌还能有效改善铸坯疏松和中心偏析状况。选择合适的电磁搅拌参数可以获得良好的铸坯质量。     

Effect of EMBr on Flow in Slab Continuous Casting Mold and Evaluation Using Nail Dipping Measurement

The nail dipping method was developed to investigate the effect of electromagnetic brake on the mold top surface flow in a certain slab caster with different casting speed and submerged entry nozzle (SEN) depth. The shape of the meniscus profile and direction of flow were quantified by analyzing the angular profile of the lump for each solidified nail, and the error evaluation for the nail dipping measurement was also determined. The results show that the meniscus level fluctuates with time variation; the electromagnetic force suppresses the high‐speed flow and decreases the meniscus flow velocity, which makes the meniscus level flatter and slower. A stronger meniscus velocity and fluctuation were created by increasing casting speed and decreasing the SEN depth. Furthermore, the effect of magnetic field on the fluid flow in the mold has been investigated.     

大方坯连铸结晶器电磁搅拌的数值模拟

对大方坯连铸结晶器电磁搅拌过程的流场和温度场进行了数值模拟,并讨论了搅拌强度对流场和温度场的影响。结果表明：在结晶器电磁搅拌下,搅拌器区域的钢液变为水平旋转,使从水口向下吐出的钢水与向上回流的钢水流股相冲突,流股侵入深度变浅,从而使轴向温度迅速降低,径向温度升高,提高了热区位置,有利于传热;搅拌强度越大,钢水的二次流现象越明显,热区位置越高。     

大方坯结晶器电磁搅拌参数对磁场分布的影响

采用有限元软件,研究了连铸470mm×350mm大方坯结晶器电磁搅拌电流和频率对磁感应和电磁力分布的影响,并与实测数值进行了对比.研究表明,磁场模拟结果与现场实测数据一致.电磁力在大方坯水平截面上呈周向分布.当电流相同时,随着频率的增加,磁感应强度减小.电磁力随着频率的增加而增加,且随着频率的增加,最大电磁力增加量减小...     

The Effects of Electromagnetic Brake on Liquid Steel Flow in Thin Slab Caster

Computational fluid dynamics (CFD) model with magneto hydro dynamics (MHD) is developed for a thin slab caster to investigate the effects of electromagnetic brake (EMBr) on liquid steel flow in continuous casting mold and to determine the EMBr practices which lead to optimal flow structure. Particle Image Velocimetry (PIV) tests in water model and meniscus flow measurements in real caster are performed to validate the predictions obtained with CFD models. The performance of different submerged entry nozzle designs, SEN 1 and SEN 2, are evaluated. The effects of nozzle submergence in relation to the applied magnetic field on mold flow structure are quantified. There are significant differences between flow structures obtained with SEN 1 and SEN 2, even though both designs have fundamental similarities and contain four ports. EMBr mainly reduces the meniscus velocities for SEN 2 as opposed to the foremost influence of EMBr for SEN 1 that is to significantly slow down the downward jet coming from the bottom ports. In addition, reducing the EMBr strength for shallow nozzle submergence and increasing the EMBr strength for deep nozzle submergence help to maintain similar meniscus activity for all conditions.     

水口结构对连铸中低碳钢流场和温度场的影响

 为研究水口结构形状对连铸中低碳钢结晶器内流场和温度场分布的影响，采用有限容积法建立连铸圆坯三维数学模型，模拟了不同水口形状下圆铸坯的流场和温度场。结果表明，在水口浸入深度为80 mm、其他参数不变时，与直水口相比，旋流水口使钢水冲击深度降低，结晶器内涡流增强，弯月面温度和二冷区凝固率提高，且随着水口数量的增加，弯月面波高和结晶器出口温度降低；采用旋流水口并施加结晶器电磁搅拌(M EMS)时，结晶器中钢液温度升高，弯月面有卷渣行为，结晶器出口未形成凝固坯壳。在实际应用中，应避免同时使用M EMS和旋流水口，或使用旋流水口时采用低强度的M EMS。     

Effect of Electromagnetic Stirring on Molten Steel Flow and Solidification in Bloom Mold

The effect of electromagnetic stirring on molten steel flow and heat transfer in a 260 mm× 300 mm bloom mold was investigated by using a method combining both finite element method and finite volume method. The simu lation results related to magnetic fields were consistent with the onsite measured data. The magnetic flux density in creased with increasing the current intensity but decreased with increasing the current frequency. Electromagnetic stirring caused molten steel to flow with rotation on a horizontal section and two sets of recirculation regions with opposite fellow directions in a longitudinal section formed. The maximum tangential velocity increased with increasing the current intensity and frequency. Furthermore, the superheat degree of the molten steel on the outlet cross section of the mold decreased with increasing the current intensity. growth zone of solidified shell in the effective stirring zone. bearing steel, the appropriate values of current intensity and to be 300 A and 3 Hz, respectively. Electromagnetic stirring caused the emergence of a zero For the 260 mm N 300 mm bloom continuous caster of current frequency of electromagnetic stirring were found     

电磁场对软接触结晶器内钢液流动的影响

采用非交错网格和适体坐标方法数值模拟了电磁场对软接触结晶器内钢液流动的影响规律。讨论了感应线圈电流强度和电源频率等因素的影响。结果表明：电磁力能加强地晶器上部熔池的搅拌强度，并在上部区域形成一明显的回流区，同时还能减小射流的渗入深度;加大电流强度，能加强钢液的回流和对钢液的搅拌，减小射流深入深度。但电流强度有一个最佳控制范围；增加电源频率，射流渗入深度增大，弯月面附近的紊动能和钢液速度提高。电源频率应控制在20kHz左右。