Large eddy simulations of double-ruler electromagnetic field effect on transient flow during continuous casting

Ramnik Singh, Brian G. Thomas, Surya Pratap Vanka

Research output: Contribution to journalArticle

Abstract

Transient flow during nominally steady conditions is responsible for many intermittent defects during the continuous casting of steel. The double-ruler electromagnetic field configuration, or "FC-Mold EMBr," is popular in commercial slab casting as it provides independent control of the applied static field near the jet and free surface regions of the mold. In the current study, transient flow in a typical commercial caster is simulated in the absence and in the presence of a double-ruler magnetic field, with rulers of equal strengths. Large eddy simulations with the in-house code CU-FLOW resolve the important transient behavior, using grids of over five million cells with a fast parallel solver. In the absence of a magnetic field, a double-roll pattern is observed, with transient unbalanced behavior, high surface velocities (0.5 m/s), surface vortex formation, and very large surface-level fluctuations (±12 mm). Applying the magnetic field suppresses the unbalanced behavior, producing a more complex mold flow pattern, but with much lower surface velocities (0.1 m/s), and a flat surface level with small level fluctuations (<±1 mm). Nail board measurements taken at this commercial caster, in the absence of the field, matched reasonably well with the calculated results, both quantitatively and qualitatively.

Original languageEnglish (US)
Pages (from-to)1098-1115
Number of pages18
JournalMetallurgical and Materials Transactions B: Process Metallurgy and Materials Processing Science
Volume45
Issue number3
DOIs
StatePublished - Jan 1 2014

Fingerprint

Electromagnetic field effects
Large eddy simulation
Continuous casting
large eddy simulation
electromagnetic fields
Magnetic fields
magnetic fields
Nails
Steel
flat surfaces
near fields
flow distribution
slabs
Flow patterns
Electromagnetic fields
grids
steels
vortices
Casting
Vortex flow

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Mechanics of Materials
  • Metals and Alloys
  • Materials Chemistry

Cite this

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title = "Large eddy simulations of double-ruler electromagnetic field effect on transient flow during continuous casting",
abstract = "Transient flow during nominally steady conditions is responsible for many intermittent defects during the continuous casting of steel. The double-ruler electromagnetic field configuration, or {"}FC-Mold EMBr,{"} is popular in commercial slab casting as it provides independent control of the applied static field near the jet and free surface regions of the mold. In the current study, transient flow in a typical commercial caster is simulated in the absence and in the presence of a double-ruler magnetic field, with rulers of equal strengths. Large eddy simulations with the in-house code CU-FLOW resolve the important transient behavior, using grids of over five million cells with a fast parallel solver. In the absence of a magnetic field, a double-roll pattern is observed, with transient unbalanced behavior, high surface velocities (0.5 m/s), surface vortex formation, and very large surface-level fluctuations (±12 mm). Applying the magnetic field suppresses the unbalanced behavior, producing a more complex mold flow pattern, but with much lower surface velocities (0.1 m/s), and a flat surface level with small level fluctuations (<±1 mm). Nail board measurements taken at this commercial caster, in the absence of the field, matched reasonably well with the calculated results, both quantitatively and qualitatively.",
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AU - Thomas, Brian G.

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AB - Transient flow during nominally steady conditions is responsible for many intermittent defects during the continuous casting of steel. The double-ruler electromagnetic field configuration, or "FC-Mold EMBr," is popular in commercial slab casting as it provides independent control of the applied static field near the jet and free surface regions of the mold. In the current study, transient flow in a typical commercial caster is simulated in the absence and in the presence of a double-ruler magnetic field, with rulers of equal strengths. Large eddy simulations with the in-house code CU-FLOW resolve the important transient behavior, using grids of over five million cells with a fast parallel solver. In the absence of a magnetic field, a double-roll pattern is observed, with transient unbalanced behavior, high surface velocities (0.5 m/s), surface vortex formation, and very large surface-level fluctuations (±12 mm). Applying the magnetic field suppresses the unbalanced behavior, producing a more complex mold flow pattern, but with much lower surface velocities (0.1 m/s), and a flat surface level with small level fluctuations (<±1 mm). Nail board measurements taken at this commercial caster, in the absence of the field, matched reasonably well with the calculated results, both quantitatively and qualitatively.

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