Mathematical modeling of the flat ingot casting process or solving automation problems

Abstract

Aluminum alloys are widely used in the production of aircraft due to their strength, lightness, corrosion resistance, and necessary electrical conductivity. At the same time, aluminum ingots used in further processing of the space industry must be of high quality. Technological problems and defects arise when temperature, speed, and other technological parameters of casting are not observed, or when modes change. At the same time, foundry processes are partially automated; the human factor significantly affects product quality and work safety. Therefore, automation of these complex processes using mathematical models to predict casting parameters is an urgent task. The goal of the work is to create mathematical models available for use in automated process control systems (APCS), as well as for the development of a digital twin. The work presents simplified formulas for modeling the temperature distribution of an aluminum ingot during the casting process, cooling the metal when moving along a metal path, and test calculations of the temperature distribution inside the ingot when the ingot reaches a fixed length. The results of this work can be used to improve the efficiency and accuracy of controlling the process of casting aluminum ingots, to eliminate emergency situations.