Abstract
Control of macrosegregation phenomena and deformation related defects is the main issue in solidification processes. Numerical modelling of casting provides an answer to industrial needs to master these defects. As a first step, it is essential to achieve a concurrent computation of the fluid flow in the bulk liquid and stress-strain evolution in the already solidified regions. For this specific purpose, a partitioned solution algorithm is developed to model both ingot casting and continuous casting processes: liquid flow induced by natural convection or filling step, solidification shrinkage as well as thermal deformation of solid phase are all taken into consideration. This article is mainly composed of two parts. In the first part, details of the model itself are described. In the second part, applications dedicated to steel solidification are proposed.
Highlights
One of the most critical modeling difficulties encountered in solidification processes is the concurrent computation of fluid flow and solid deformation
A partitioned solution algorithm is developed to model both ingot casting and continuous casting processes: liquid flow induced by natural convection or filling step, solidification shrinkage as well as thermal deformation of solid phase are all taken into consideration
A new algorithm of concurrent and coupled resolution of fluid flow and solid deformation has been developed for both ingot casting (IC) and continuous casting (CC) processes
Summary
One of the most critical modeling difficulties encountered in solidification processes is the concurrent computation of fluid flow and solid deformation. Macroscopic governing equations are developed by using the volume averaging method, scaling up physical problems from its dendritic scale to that of the cast product These equations are coupled and solved in a single resolution system [1, 2]. Zhang et al [4] proposed an original partitioned solution algorithm for the current modeling of fluid flow and solid deformation for solidification processes. This algorithm was developed under the specific hypothesis that the movement of the solid phase is negligible compared to that of the fluid flow, which is true for most ingot casting (IC). The present paper includes a synthetic presentation of the resolution scheme, followed by an application to a three dimensional (3D) industrial CC process
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