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Simulation of direct chill casting under the influence of a low-frequency electromagnetic field

机译：低频电磁场影响下的直接冷硬铸造模拟

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摘要

A comprehensive, multiphysics, meshless, numerical model is developed for the simulation of direct chill casting under the influence of a low-frequency electromagnetic field. The model uses mixture-continuum-mass, momentum and energy-conservation equations to simulate the solidification of axisymmetric aluminium-alloy billets. The electromagnetic-induction equation is coupled with the fluid flow and used to calculate the Lorente force. The involved partial-differential equations are solved with the meshless-diffuse-approximate method by employing second-order polynomial shape functions and a 13-noded local support. An explicit time-stepping scheme is used. The boundary conditions for the heat transfer involve the effects of hot-top, mould chill and direct chill. The use of a meshless method and the automatic node-arrangement generation made it possible to investigate the complicated flow structures in geometrically complex inflow conditions, including sharp and curved edges, in a straightforward way. A time-dependent adaptive computational node arrangement is used to decrease the calculation time. The model is demonstrated by casting an Al-5.25wt%Cu aluminium alloy billet with a radius of 120 mm. Results on simplified and realistic inflow geometry are considered and compared. The effect of the low-frequency electromagnetic force on the temperature, liquid fraction and fluid flow are investigated under different current densities and frequencies.
机译：建立了一个全面的，多物理场的，无网格的数值模型，用于模拟在低频电磁场影响下的直接冷硬铸造。该模型使用混合连续质量，动量和能量守恒方程来模拟轴对称铝合金坯的凝固。电磁感应方程与流体流耦合，并用于计算洛伦特力。通过采用二阶多项式形状函数和13个节点的局部支撑，用无网格扩散近似方法求解所涉及的偏微分方程。使用显式的时间步长方案。传热的边界条件包括热顶，模具冷却和直接冷却的影响。无网格方法的使用和节点自动排列的生成使直接研究几何复杂的流入条件（包括尖锐和弯曲的边缘）中的复杂流动结构成为可能。时间相关的自适应计算节点布置用于减少计算时间。通过铸造半径为120 mm的Al-5.25wt％Cu铝合金坯料来演示该模型。考虑并比较了简化和逼真的流入几何形状的结果。研究了不同电流密度和频率下低频电磁力对温度，液体分数和流体流动的影响。

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