板坯连铸结晶器内凝固坯壳的三维数值模拟

基于流场和温度场的计算,对断面为1 780 mm×225 mm的板坯结晶器进行数值模拟,考虑3种不同水口条件下,钢液流动对凝固壳的冲刷,计算出凝固壳厚度的三维分布特征,并与二维切片法的计算结果进行了对比。结果表明：有水口时结晶器角部位置凝固壳最大值为约45 mm,宽面和窄面中心凝固厚度壳最大值为24 mm,分别比无水口条件下凝固壳薄1~2 mm;钢液的扩散会使凝固壳在距离结晶器角部300 mm和顶部400 mm的位置形成约深度2.5 mm的凹陷;同时钢液会冲刷整个结晶器窄面的凝固壳,在窄面中心最严重;对比不同的水口,凸底水口冲刷最大,凹底最小。     

Finite Element Method of 3D Stable Heat Conduction of Steel Fluid in Continuous Casting Moulds

The heat transfer of steel fluid in continuous casting mould is a stable process and can be depicted with three-dimensional stable heat conduction equation depending on tension speed. The corresponding finite element equation, including the first, second and third boundary conditions, is deduced out with Galerkin residual method. The coded FEM program is used to analyze the temperature distribution of Q235 steel in continuous billet casting mould. The method proposed is a foundation of thermo-mechanical coupled analysis for the formation of solidified shells and stress in the shells in continuous casting.     

An optimization method for the nozzle arrangement in secondary cooling zone of continuous casting

Based on the existing research on nozzle arrangement method in secondary cooling zone of continuous casting, the method of superposed water flow density is put forward to optimize the nozzle arrangement at casting direction and transverse section of slab according to the optimization principle. The two-dimension heat transfer model is established. The solidification morphology of cross-section at casting direction is simulated with consideration of the influence of water flow density inhomogeneity on solidification process at transversal section, and the temperature distribution of slab, solidification process, and quality of slab are compared between before and after optimization. The results indicate that the surface temperature of slab is dropped equably after optimization, and the casting blank is cooling uniformly in the water springing zone so as to ensure better quality of the casting blank.     

Dynamic Control Model for the Secondary Cooling of Slab Casting Based on Neural Networks

A dynamic control model for the secondary cooling of slab casting is presented to reduce the difference between the actual temperature and the goal surface temperature of slab. The model, which is based on the BP neural networks for forecasting the temperature and the fuzzy neural networks for dynamically controlling the water in the secondary cooling in the continuous casting, could timely adjust and allocate the water according to the speed and temperature of slab. A series of tests have been conducted based on inputs of the No. 2 slab caster in a steel plant. It has been shown that the model, which integrate the charateristics of water controlling problem in secondary cooling into the temperature status of slab during the cooling process, can control the water in secondary cooling efficiently and dynamically according to the situation of actual production.     

Numerical simulation and optimization of flow and temperature fields for wide slab cast mold

Fluid flow and temperature distribution in a wide slab continuous caster mold are simulated using the commercial software FLUENT. The research results show that the longitudinal cracks in the wide slab surface with an original submerged entry nozzle (SEN) mainly are caused by weak upper flow circulation in the mold, slow heat exchange near the meniscus, and non uniform melting of the mold powder. Therefore, a modified SEN with smaller outlet thickness, a 15° downward port angle, and convex bottom is designed to overcome the disadvantages of the original nozzle. The characteristics of the molten steel flow are analyzed by numerical simulation. The results indicate that the parameters of the optimum SEN are more highly optimized than the original SEN. The trial results also show that the optimum SEN possesses a better application effect.     

Numerical Simulation of Temperature Field during the Dissolution-Diffusion Bonding Process to Mending Iron Casting Defects

The common finite element method microcomputer software for simulation of the temperature field is developed by authors. It is used for calculating the temperature field duringthe mending process of iron casting defects by means of the dissolution-diffusion bonding technology. The correctness has been proved by testing results. This software has been used to analyse thecaused of hardness rising in heat effecting zone,and also find out the approach for solving the problem.     

The Mathematical Model of Cooling and Heat Transfer for the Solidification of Thin Slab during Continuous Casting Process

In the established model, the cooling differences are considered between the surface of inner radius and that of outer radius, and in the transverse direction of thin slab. And the conception for the effective coefficient of spraying water in continuous casting is firstly put forward. According to different casting speeds and different cooling zones, different time step lengths are adopted. In this model the heat transfer differences are thought over among vertical and curved zones, wide and narrow surfaces an well as angular zone of mould. The method of the corrected equivalent specific heat is used to deal with latent heat. The influence of forced convection is considered on heat transfer. Therefore, the model has higher accuracy and is consistent with the practice.     

Advance in Mathematic Model of Solidification Heat Transfer Process in Continuous Casting

The mathematic model of solidification heat transfer process in continuous casting strand is useful for quantitatively analyzing heat transfer in continuous casting process, quality control and process control. The heat transfer in continuous cast strand in crystallizer and secondary cooling zone have been analyzed. The attention has been paid to basic logic and methodology in model building up. Typical methods determing solution condition and parameters for the model have been discussed. Some numerical methods at the present time for solving solidification heat transfer model, such as finite difference method, finite-element method and boundary element, have been investigated comparatively. In the future, working on solidification heat transfer model, which is more practical, and the integration of the control model will play an important role in the development of high efficiency continuous casting technology.     

3-D Finite Element Analysis of Solidified Shell in Molds for Continuous Casting of Thin Slabs

A three-dimentional thermal elastoplastic contact FE analysis model of solidifiedshell in moulds for continuous casting of thin slabs is set up, based on the known geometry of theshell and the temperature distribution in the shell. We in turn obtain the stress and Strain distributions of the solidified shells formed in lSP and CSP moulds,the gap distributions between the Shellsand the mould walls,as well as the curves of cracking index [1] in the shells,which provides afoundation for the design and control of technical parameturs for continuous casting of thin slabs.     

Evaluation on the Damage Evolution of the CRCP+AC Composite Pavement by the Concrete Dameged Plasticity Material Model

In the study on the CRCP+AC composite pavement, the form and distribution pattern of cracks are two important factors influencing the performance and the lifetime of the pavement. The concrete damaged plasticity material model incorporated in the general purpose finite element software named ABAUQS was adopted to describe the mechanical characteristics of the CRC slab. Combining with the temperature field database drawn from the three-dimensional transient heat transfer analysis, the structural damage under the condition of temperature changing is analyzed. The structural damage evolution and the crack behavior of the CRC slab subjected to the thermal-mechanical coupling condition are further analyzed, which suggests that the role of the asphalt concrete surface is not confined only to the scope of improving the performance of the road, its capacity for improving the stress state of CRCP slab is worthwhile to be affirmed. And the reasonable thickness of AC layer should be designed in consideration of the thermal contraction and damage properties of the CRC slab comprehensively.     

Grain growth of continuous casting slab solidification based on cellular automata model

The cellular automaton (CA) method is coupled with finite difference method to establish a stochastic nucleation and growth model. According to the actual production conditions, the solidification structure of continuous casting slab is simulated and the evolution law of the inner structure is reconstructed. It is showed that grain transformation is from equiaxed crystal to columnar crystal and then to equiaxed crystal. Thickness of three crystal layers are different in various production technological systems, thickness of surface equiaxed crystal and inner equiaxed crystal are reduced, and the results of the columnar crystal thickness are contrary, while casting speed and superheat are increasing. The results show well agreement with the stochastic nucleation, preferred growth, competitive growth and random orientation of grain.     

Control model for secondary cooling of continuous casting based on compensation temperature of the difference between liquidus and solidus

During continuous casting process, the composition of molten steel often varies with different heats, which leads to the big fluctuation of billet surface temperature when the traditional parameter water control model is applied to control the process. Additionally, it is difficult to keep the temperature at the straightening point of the billet within a reasonable range. Given above consideration, a new control model for secondary cooling of continuous casting based on compensation temperature of the difference between liquidus and solidus has been presented. Meanwhile, the temperature field of the billet is simulated with both the parameter water control model and the new secondary cooling control model, and the results indicate that the new control model for secondary cooling of continuous casting could perform better when it is used to control the surface temperature at straightening points of billet, thereby ensuring the quality of the billet.     

Prediction Model of Intermixing Slab Length During Continuous Casting Grade Transition Process

In order to increase decision accuracy of the intermixing slab length and position, and decrease the slabs which are offgraded or scrapped. Water model experiments were conducted to simulate the continuous casting grade transition process of No. 2 continuous caster at Bao Steel. The dimensionless concentration profiles along slab length with different continuous casting conditions were measured. Based on the profiles a mathematical model was developed to predict the final composition distributions and length of intermixing slab. Comparison of predicted dimensionless concentration profile with plant data shows that the precision of the model is considerably satisfied to meet the need of steel grade transition evaluation.     

Using a genetic algorithm to optimize secondary cooling water distribution in slab casting

A genetic algorithm was used for coding the volume of cooling water in the secondary cooling zone based on the heat transfer model in real time production. This was done to improve the dynamic control of the secondary cooling water in high efficiency continuous casting. The fitness function of multi objective optimization in the algorithm is in accordance with the distribution of metallurgical criteria. The genetic algorithm was integrated with the metallurgical criteria and the heat transferring model to optimize the water distribution. These steps increase the distribution adaptability and improve its efficiency compared to the traditional optimization methods of solving multi objective optimization and other non linear problems. Simulation using the process data of the No.2 slab caster in the Steelmaking Plant of Panzhihua Iron and Steel and on site testing were carried out. The results show that the optimized distribution saves 2% of water than without optimization, while water distribution along the slab to the water gradually decreases in accordance with requirements for slab quality control.     

The Numerical Simulation of Casting Process for Making Metal Matrix Composites

In this paper,a numerical simulation of the casting process for making the MMC.using the PEM, is studied.The convection of liquid metal and the release of latent heat of solidification are taken into account.The algorithm and program for axisymmetric casting model are developed to the problem of coupling between flow and heat transfer,as well as phase change.The variational curves of temperature,the position of flow front and the distrsbutions of volume fraction of solid metal in matrix and their variation with time are obtained.The influences of technological paarmeters to casting are discussed.     

Dynamic Control Arithmetic and Modeling of Secondary Cooling System for ROKOP Billet Continuous Casting

A dynamic control arithmetic and mathematic model of secondary cooling system for ROKOP billet concasting has been developed in view of the changes of casting speed during concasting process and the high fluctuation of surface temperature due to the use of static control method. By means of computer simulation and by comparison between static and dynamic control method, it proves that the latter one is more adaptive to the changes of casting speed, which leads to lower fluctuation of surface temperature.     

Effect of B2O3 on the physico-chemical properties of mold slag used for high-Al steel

A new mold slag with low content SiO2 and high content Al2O3 is designed in order to avoid or alleviate the reaction between Al and SiO2 during the continuous casting of high-Al steel, the acidity of this slag is adjusted by adding B2O3, and the effect of B2O3 content on the fusion property, viscosity property and heat transfer characteristics through the mold slag film of the mold slag is analyzed. The results show that the fusion temperature, viscosity, viscous flow activation energy decrease and heat flux through the slag film increases with the increase of B2O3 content in the range of 4%~10%; temperature time transformation (TTT) diagrams move to longer incubation time with the increase of B2O3, while the crystallization speed of mold fluxes decreases; under this experiment condition, the precipitation of CaF2 crystals can be restrained by the increase of B2O3 content in the mold slag.     

Study on Temperature Fiele of Cast Iron Compound Roll in Slab Hot Rolling

In this paper,a finite element method coupling thermo-elasticity is used to ana-lyze the temperature field of cast iron compund roll in hot rollin8 slab mill.A technique to deal withthe bou ndary of heat and load in rotation is developed.     

CCD radiation temperature measurement method for hot continuous casting billet surface

According to the present research status and existing problems of hot continuous billet surface temperature non contact measurement technology, a real time temperature measurement model, which combines two-color(R,G) and monochrome (B) of surface radiation image, is established. The surface image is collected through tricolor charge coupled device (CCD) sensor, at the same time, the temperature dynamic response range of CCD can be improved by controlling integrated time and setting different apertures. Through computer image process technology, multi-point temperature can be measured simultaneously, and 2-D temperature field distribution on continuous casting billet surface can be realized. It is be proved by theory and application that the model and method can provide a theory and technology support for realizing surface temperature field on-line measurement for continuous casting billet.     

Two-dimension Thermal Elasto-plastic and Creep Stress Model for Thin Slab Strand in Continous Casting

The thin-slab continuous casting is an important new technology in the world. The major key of this technology is to assure the good quality and the less crack of thin slab. Thus in this paper a two-dimension thermal elasto-plastic and creep stress (TEPC) model for thin slab strand is developed. The equations between stress and strain are given on thermal creep condition for elastic area, plastic area and the transitional area of thin-slab strand section.The formula of equivalent plasto-strain increment is obtained. The boundary conditions of the model given is fairly accurate. Therefore, the TEPC model is possessed of higher precision, and the model is also used to analyze the stress and strain distribution of strand in continuous casting.