Abstract
A novel digital design methodology that combines computational fluid dynamics (CFD) modelling and Taguchi-Grey relational analysis method was presented for a single-strand tundish. The present study aimed at optimizing the flow control device in the tundish with an emphasis on maximizing the inclusion removal rate and minimizing the dead volume fraction. A CFD model was employed to calculate the fluid flow and the residence-time distribution of liquid steel in the tundish. The Lagrangian approach was applied to investigate the behavior of non-metallic inclusions in the system. The calculated residence-time distribution curves were used to analyze the dead volume fraction in the tundish. A Taguchi orthogonal array L9(3^4) was used to analyze the effects of design factors on both single and multiple responses. Moreover, for the purpose of meeting the multi-objective target functions, grey relational analysis and analysis of variance were used. The optimum positions of the weir and the dam were obtained based on the design targets. A special focus of this study was to demonstrate the capabilities of the Taguchi-Grey relational analysis method as a powerful means of increasing the effectiveness of CFD simulation.
Highlights
The tundish, working as a buffer and distributor of liquid steel between ladle and continuous casting (CC) molds, plays a key role in affecting the performance of the CC machine, solidification of liquid steel, quality, and productivity [1,2]
This study demonstrated that the digital design, using the advanced computational methods, can be a significant technology for particles of industrial design
The computational fluid dynamics (CFD) model was validated against the water model experiments reported in the literature by
Summary
The tundish, working as a buffer and distributor of liquid steel between ladle and continuous casting (CC) molds, plays a key role in affecting the performance of the CC machine, solidification of liquid steel, quality, and productivity [1,2]. Tundish design varies widely from plant to plant, owing to the differences in the end products, number of strands, and operating parameters. An optimum tundish design aims at providing maximum opportunity for the control of liquid steel flow, heat transfer, mixing, and inclusion removal. Considerable efforts have been made in both academia and industry over many decades to fully exploit and enhance the metallurgical performance of the tundish [3,4]. Computational fluid dynamics (CFD) and water model experiments have been considered as useful and promising tools that can accurately predict many phenomena of practical interest in tundish. A summary of the previous published modelling works can be found in the references [5,6]
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