板坯连铸结晶器内铸坯凝固及变形的热力耦合有限元分析

建立板坯连铸结晶器内凝固坯壳形成及其应力和变形的热力耦合有限元分析模型,采用二维瞬态热传导有限元方法分析温度场,采用二维热弹塑性接触有限元方法计算应力分布。编制了有限元程序,计算分析了三种结晶器锥度、三种拉坯速度和三种保护渣层情况下,结晶器内Q235铸坯凝固坯壳的形成过程。得到凝固坯壳的温度场、厚度、变形、与结晶器壁间的气隙以及应力分布等,得到该三种工艺参数对结果的影响规律。     

新型圆坯结晶器铜管结构模拟优化设计

为优化设计新型圆坯结晶器铜管结构,提高结晶器寿命和铸坯质量,利用商业有限元软件ANSYSTM建立二维连铸结晶器内钢水凝固传热及弹塑性应力有限元瞬态分析模型,铸坯传热边界采用与气隙相关的热流密度修正函数,建立与温度相关的热物性参数、力学性能和屈服函数,并利用多场间接耦合的方式对不同工况下的4种圆坯在结晶器内的凝固收缩变形过程进行数值模拟.结果表明,钢种和工况条件对铸坯边界凝固收缩过程影响显著,6瓣模型为4种计算模型的最优形状,依据铸坯边界凝固收缩曲线和新型结晶器设计准则,新型结晶器铜管结构设计采用凸型花瓣状内腔和大锥度设计.     

异型坯结晶器与铸坯热力耦合数值模拟

为研究异型坯连铸结晶器内铸坯凝固和变形过程,采用ABAQUS软件建立了异型坯连铸结晶器和铸坯的二维瞬态热力耦合有限元模型,编制ABAQUS用户自定义子程序GAPCON实现结晶器内壁和铸坯之间的传热模拟.计算模型中考虑了铸坯的凝固和热变形、气隙对传热的影响以及铸坯与结晶器之间的接触应力.分别对2种不同水缝设计结晶器进行了数值模拟,数值分析结果表明,小孔水缝设计的结晶器温度峰值较低、热面温度分布更均匀,因而比大孔水缝设计结晶器具有更长的使用寿命和更优的铸坯质量,这一结论与现场试验结果一致.     

零方程湍流模型在列车车厢内气流数值模拟中的应用

采用k-ε湍流模型对列车车厢内气流进行数值模拟需要消耗大量的计算时间，为此，提出了采用零方程湍流模型对列车车厢内的气流组织进行数值模拟；分别采用零方程湍流模型与k-ε湍流模型对列车车厢内的空气流动及传热进行了数值计算，经分析比较可知，该两种湍流模型的数值计算结果吻合程度较好，采用零方程湍流模型可大大缩短计算时间，利用其简单、快捷的特点，可以为列车空调系统的工程设计提供简便的数值模拟方法。     

连续铸钢中结晶器冷却水温差的测量和水量调节

一、前言如众所知,结晶器冷却水进出水的温度差,取决于结晶器内钢水温度的高低和凝固的情况,而钢水的凝固情况又决定了钢锭的拉速。因此,为了实现目前连续铸钢工艺中较先进的“低温高速”技术,除了控制好大包和中间包的钢水温度外,还需要对结晶器冷却水的温差进行准确测量和对流量合理调     

FTSC薄板坯连铸结晶器内的热/力行为研究

基于SPHC钢在H2结晶器内的凝固过程,利用有限元软件ANSYS中的单元生死技术,通过改变薄板坯单元的状态建立其在结晶器内随时间变化的二维非稳态模型。模拟出薄板坯在结晶器不同部位处的温度场及应力场分布情况,其结果可为优化结晶器锥度及改善薄板坯质量提供理论依据和技术基础。     

高温合金电磁软接触近净成形定向凝固研究

传统高温合金叶片类铸件制备过程中,熔体长时间受到陶瓷模壳材料的污染,性能难以提高,借助于电磁软接触成形技术中的电磁压力使高温合金熔体呈半悬浮状态,减少了熔体与磁模结晶器的接触面积和时间,提高了合金熔炼和成形的纯净度,同时将该技术和定向凝固技术相结合开发了一种实现高温合金复杂形状电磁软接触成形定向凝固的工艺,并探讨了该工艺下3种结晶器材料（陶瓷、磁模和石墨）中磁感应强度的分布规律,结果表明,石墨套高度对磁模结晶器磁感应强度的大小和分布以及熔体温度场有很大影响。通过调整上下线圈功率和抽拉速度等工艺参数成功地制备了大小两种近叶片形状的高温合金电磁软接触成形的定向凝固样件。．     

中碳钢连铸方坯内部角裂机制研究与优化

分别选取西钢某厂实际生产中易发生内部角裂缺陷的40Cr和45钢连铸坯为研究对象,通过对缺陷采用热酸浸低倍试验、金相法和探针能谱分析,发现缺陷处不存在明显的组织异常和质点沉淀。运用ANSYS软件对连铸结晶器凝固过程进行热模拟。研究结果表明,缺陷形成于结晶器内的凝固过程,根本原因是铸坯在结晶器中凝固传热不均导致出现铸坯偏角区热节区效应,从而诱导产生热应力,致使沿柱状晶晶间铁素体开裂,并伴随一定量的铸坯鼓肚现象。通过重新设定结晶器铜管圆角半径和优化生产部分工艺后,最终使连铸坯内部角裂评级在1.0级以上的比例下降到10.42%。     

不同湍流模型下旋转叶片气固耦合动力学特性的研究

本文对轴流式压气机内旋转叶片在不同湍流模型的气固耦合作用下的动力特性进行了研究。利用FSI（fluid-structure interaction）的双向顺序耦合算法,采用CFX和ANSYS对压气机内气体和旋转叶片分别计算,并通过迭代求解,获得叶片在气流作用下的动力学响应。为了研究耦合场内对叶片动力特性的影响,本文对某一级转子叶片进行流固耦合计算,由于在模拟流场计算中,不同的湍流模型对计算结果影响较大,采用3种湍流模型：标准κ-ε湍流模型(standard κ-ε)、重正化群κ-ε湍流模型（renormalization group κ-ε,RNG κ-ε）和大涡湍流LES模型（Large eddy simulation）,获得了叶片在瞬态流场变化下的动力特性,并比较了不同湍流模型对计算的影响,为工程上对压气机内转子工作特性的分析提供一个可行的方法。     

管式结晶器电镀设备及其电镀工艺

本发明提供了一种方坯连铸机用的管式结晶器铜管内壁电镀设备和利用这种设备对管式结晶器进行电镀的工艺。该电镀设备包括镀液贮槽、过滤装置及相关的控制装置和连接管路，其电镀槽由作为电镀阴极的管式结晶器铜管、夹具密封盖、阳极钛篮组成，电镀工艺是将结晶器内表面脱油处理后，用含有氨基磺酸钴、钨酸钠、氯化氢、硼酸、十二烷基硫酸钠、     

利用电磁力的新型连续铸造技术

结合电磁流体力学的基本理论,介绍了几种利用电磁力的新型连续铸造技术,包括利用交换磁场的电磁铸造,冷坩埚熔炼和钢的连续铸造初期凝固控制技术及利用稳恒磁场的电磁闸,连续铸造双层钢和水平电磁铸造技术等。     

双金属复合材料双结晶器连铸工艺研究

总结了双金属连铸技术的研究开发现状，提出了双金属复合材料双结晶器一次铸造连续成形新工艺。以Ｐｂ和Ｐｂ－Ｓｎ共晶合金作为试验材料，在自行设计和制造的双结晶器连铸试验样机上进行了成形试验。结果表明：本文提出的双金属复合材料双结晶器一次铸造连续成形新工艺是可行的；采用该工艺成功地制备了内坯Ｐｂ与包覆金属Ｐｂ－Ｓｎ合金之间为冶金结合的复合材料；影响连铸复合材料质量的主要因素是两种金属的浇注温度和拉坯速度。     

Numerical analysis of the twin-roll casting of thin aluminium-steel clad strips

The production of thin aluminium-steel clad strips by means of twin-roll casting is one of the prospective trends in the development of sheet production. The main advantages of twin-roll casting are low specific energy and resource consumption. Besides this, the resulting compound has a high bonding strength owing to the presence of a continuous thin layer of intermetallic phases having an approximate thickness of 3 µm at the interface of the two metals. At the same time, the quality of the clad strip depends on the microstructure and properties of the aluminium layer formed directly from a melt. A deformation immediately following the solidification of the metal between the two rotated, internally water-cooled rolls has a substantial influence on this aluminium layer. Due to the complexity of observing the processes occurring in the melt pool, a numerical simulation became one of the main methods for their investigation. Simulation is widely used to describe the process of twin-roll casting of monomaterial strips, but so far it has not been used for to comprehensively analyse the process of twin-roll casting of clad strips. In the present paper, a two-dimentional finite-element simulation of the system “clad strip—water-cooled rolls” using the ANSYS software is proposed. A joint analysis is carried out of the heat transfer, viscous flow of aluminium melt, its solidification and deformation resulting in the temperature distribution in the cast metal as well as in the tool. The dependences of the deformation strain and outlet temperature of the clad strip on the main technological process parameters; obtained by numerical simulation, are shown.     

Numerical Modeling of Grain Structure in Continuous Casting of Steel

A numerical model is developed for the simulation of solidification grain structure formation (equiaxed to columnar and columnar to equiaxed transitions) during the continuous casting process of steel billets. The cellular automata microstructure model is combined with the macroscopic heat transfer model. The cellular automata method is based on the Nastac's definition of neighborhood, Gaussian nucleation rule, and KGT growth model. The heat transfer model is solved by the meshless technique by using local collocation with radial basis functions. The microscopic model parameters have been adjusted with respect to the experimental data for steel 51CrMoV4. Simulations have been carried out for nominal casting conditions, reduced casting temperature, and reduced casting speed. Proper response of the multiscale model with respect to the observed grain structures has been proved.     

Cold model for process of a Ni-aluminide/steel clad pipe by a reactive centrifugal casting method

A novel method (reactive centrifugal casting method) to fabricate a Ni-aluminide/steel clad pipe has been proposed. Ni powder was placed on a spinning steel pipe, and Al liquid was poured into the steel pipe. The Al liquid and Ni powder exothermically reacted and produced a composite layer consisting of Ni-aluminides on the inner surface of the steel pipe. The heat generated by the exothermic reaction melted the inner surface of the steel pipe and bonded the composite layer to the steel. However, during the process, the Ni powder moves along the flow of the Al liquid. In this study, in order to obtain a better understanding of the Ni powder motion in the spinning steel pipe, a cold model centrifugal casting is employed. We focus on the effects of the angle between the spinning and horizontal axes on the type of centrifugal casters, because it is difficult to obtain the same data by the proper experiments.     

A System of Process Models for Estimating Parameters of Continuous Casting Using Near Solidus Properties of Steel

The quality of a continuously cast product depends on the process condition, which, in turn, depends on process parameters. To be able to set the correct parameter values, it is important that behavior of the steel being cast under different casting conditions is well understood. This will need the knowledge of the mechanical behavior of steels at temperatures near the solidus. This paper presents, in detail, how these properties were modeled as a function of steel grade, temperature, and stresses that arise during casting. These models have been used to develop an integrated system that is capable of simulating various process conditions that may be encountered during continuous casting. The details of how these models were developed, verified, and used to develop the integrated system are presented in this paper.     

基于CAFE模拟双辊连铸纯铝凝固微观组织

鉴于双辊薄带连铸等轴晶区半固态铸轧组织对产品性能的重要性,基于热传输、流动传输、溶质传输等基本传输过程以及晶粒生长物理过程,建立了双辊连续铸轧纯铝凝固过程的宏观温度场、浓度场、微观组织及枝晶形貌演化的三维数学模型.采用CA-FE法对双辊连续铸轧纯铝在水冷钢辊连续铸轧中的凝固过程进行了模拟,采用光学显微镜研究了铸轧工艺参数对凝固组织的影响.数值模拟结果表明,所建立的数学模型能够合理描述晶粒沿任意角度生长的过程,温度场、溶质场和微观组织形貌的模拟计算结果合理.模拟结果与实验结果基本吻合,检验了模型的正确性.     

Simulation and application of dynamic heat transfer model for improvement of continuous casting process

Abstract

Numerical simulation is being increasingly used to improve the existing cooling systems. In order to attain highest quality strand, a two-dimensional dynamic mathematical heat transfer model of billet continuous casting of low carbon steel has been presented. This model can be used to compute the billet temperature distribution and shell thickness, especially it can be used to simulate the solidification process which is caused by frequently variational casting conditions. The fluctuation of measured temperature has been reduced to <10°C with thermal imaging system. The online model can monitor surface temperature and shell thickness in the casting process. So it provides the possibility for the online process control. For the validation of the dynamic model, a lot of billet surface temperature and shell thickness measurement were carried out on an actual casting machine. Finally, the dynamic model has been used for adjusting the operating parameters to improve the casting speed.     

An integrated,finite element‐based process model for the analysis of flow,heat transfer,and solidification in a continuous slab caster

An integrated, finite element‐based process model is presented for the prediction of full three‐dimensional flow, heat transfer, and solidification occurring in a continuous caster. Described in detail are the basic models for the analysis of turbulent flow and heat transfer in the liquid steel zone, in the zone of mixture of the liquid steel and solidified steel, and in the solidified zone. Then, the models are integrated to form a process model which can take into account the strong interdependence between the heat transfer behaviour and the flow behaviour. The capability of the process model to reveal the detailed aspects of turbulent flow, heat transfer, and solidification occurring in a continuous caster is demonstrated through a series of process simulations. Copyright © 2003 John Wiley & Sons, Ltd.     

Influence of surface roughness on the bonding quality in twin-roll cast clad strip

Manufacturing of aluminum-steel clad strips by means of twin-roll casting is of great interest due to a shorter production chain in comparison with convenient technologies. Experiments on twin-roll casting of clad strips of pure aluminum and an austenitic stainless steel of 2.5?mm total thickness with the inline abrasive cleaning of a steel substrate’s surface performed. The corresponding device for the inline surface preparation is designed. The influence of surface roughness of the substrate’s surface on the bonding strength between strip layers is analyzed. The mechanism of intermetallic bonding on the roughened surfaces is discussed. It is shown that surface roughness of steel substrate up to 4.2?µm provides bonding strength above 100?MPa.