Mold Flow Research Articles

Effect of swirling flow tundish submerged entry nozzle outlet design on multiphase flow and heat transfer in mould

ABSTRACTEffect of a swirling flow SEN (submerged entry nozzle) outlet design on the multiphase flow and heat transfer in a mould was investigated by using numerical simulation. It was found that different SEN outlet designs could form different flow patterns and temperature distributions on the upper of the mould. The enlarged outlet SEN design had an effect to decrease the horizontal velocity of liquid steel flowing out the SEN outlet, reducing the steel flow velocity towards the solidification front. Although a higher velocity was found near the slag/steel interface with the enlarged outlet SEN, but the turbulent kinetic energy was lower. The reason was that less circulation flows were formed in the region of the mould top. The weak horizontal flow towards the solidification front with the enlarged outlet SEN induced lower wall shear stresses, at the same time it also formed a lower temperature distribution near the solidified shell.

Recognition and Simplification of Holes in CAD Models of an Injection Mold for Mold Flow Analysis

Recognition and Simplification of Holes in CAD Models of an Injection Mold for Mold Flow Analysis

IMPACT AND WATER FLOW STUDIES OF COMPONENTS FORMULATION FOR MIXING PROCESS CONTAIN OF POLIPROPHYLENE AND HOT MIX ASPHALT PENETRATION 60/70.

The thermoplastic Poliprophylene (PP) powder were mixed with Hotmix Asphalt 60/70 system to produce feedstock for sample of Asphalt pavement by using mixer and mold flow adviser simulation. The combination of 6%,7% poliprophylene and hotmix asphalt penetration 60/70 were choosen with various formulation adopted to attain optimum feedstock properties. Two different kinds of components system are poliprophylene with composition 6%,7% and hotmix asphalt penetration were deeply in investigated. It is found that the water flow of pure asphalt is 0,91 MPa, combination asphalt and poliprophylene 6% is 1,09 MPa, Asphalt and prophylene 7% is 1,33 MPa. The absorbtion of water for poliprophylene 6% and 7% is higher than pure asphalt, but the impact of asphalt combined with poliprophylene higher than the impact of pure asphalt. The results of simulation of mold flow advisor, water flow is faster 13,57 second than manual method 22,55 second.

Mold optimization design of metal powder injection product USB interface based on Mold Flow analysis

Metal powder injection molding technology (metal injection molding, the MIM) can achieve a mass in the small and medium-sized complex shape product preparation, low cost, which is of great significance in promoting the production of products and applications.In this paper, taking the USB interface parts made of 17-4ph stainless steel as an example, through scheme verification, the optimized and reasonable die structure is obtained, the 3d modeling of the parts is carried out with UG, and MoldFlow software is used for MoldFlow analysis.The design cycle is shortened and the design quality is improved.

Numerical Simulations of Electromagnetic Counteractions to Mold Fluid Flow Asymmetry Deviations

Asymmetric flow of the molten steel in a continuous slab casting mold may be detrimental to the quality of the solidified end product. Depending on the severity of the biased flow, local mold powder entrainment, non-homogeneous solidification around the perimeter of the initial shell or non-optimal inclusion seclusion may occur. In particular, nozzle clogging in the last slabs before an SEN exchange may cause strong and asymmetries in the upper regions of the mold. To avoid costly downgrades of steel quality in these slabs, it is vital to maintain stable and symmetric fluid flow conditions in the mold. The EMBR and the FC Mold are two flexible electromagnetic devices able to produce asymmetric braking/stirring along the width of the mold in slab casting, and in this way allow counteraction against e.g. biased mold flow or local excessive flow speeds. Numerical computations of mold fluid flow and magnetic flux have been carried out to quantify the required fields to symmetrize biased flow scenarios caused by e.g. SEN clogging. In conjunction with steel plant trial feedback, the simulation results have been used to setup control algorithms for the EMBR and FC Mold.

Influence of Fine Al2O3 and Aluminium Nano-Particles on the 6061 Aluminium Alloy near the Grain Boundary of the Semi-Solid Cast Microstructure

Dual mixed slurry for AA6061/Al2O3-Al powder was formed under argon gas protection and used to fabricate composite due to the effect of free vortex flow in semi-solid stage. Initially, Al2O3 reinforcement was mixed with aluminium powder via ball milling process and then converted into reinforcement slurry. Simultaneously, primary slurry for AA6061 alloy was prepared in closed coiled sprue. Semi-solid thick slurry was prepared for a consolidated effect of liquid reinforcement addition and solid-liquid dispersion on the cast microstructure. Finally, this mixed slurry was free to flow in open mould in free vortex flow and 668oC melt temperature condition. Observations from the microstructure, EDX and XRD reveal that Al2O3 particles and aluminium particles are segregated near the grain boundary and potentially provide an effective joining between the matrix and reinforced particles. Mechanical characteristics for tensile and impact strength for Al2O3 addition confirms a significant improvement on these properties of the AA6061 alloy.

Injection Mold Analysis Based on Moldex3D Car dashboard back cover Casting System

This paper is the injection mold design of the car dashboard back cover casting system. Two different types of gating systems for cold and hot are analysed and processed for mold structure design and problems that may arise during the production process of plastic parts. Moldex3D mold flow analysis software was used for simulation, and two different types of gating systems were analysed and compared. It is found that the advantages and disadvantages of different casting systems exist and the optimal design scheme is selected to improve the mold structure design and improve the production qualification rate of plastic parts.

Optimization of the Flow in a Slab Mold with Argon Blowing by Divergent Bifurcated SEN

Optimization of the Flow in a Slab Mold with Argon Blowing by Divergent Bifurcated SEN

Determination of an Optimized Submerged Entry Funnel (SEF) Configuration for Beam Blank Mould

A three-dimensional mathematical model is validated and established for studying the fluid flow inside a beam blank mould. Comparison of the model result with results available in public domain is done to validate the numerical analysis technique. Flow characteristics of a 430 mm × 350 mm × 90 mm beam blank mould have been studied with five different SEF configurations, namely (a) straight bore, (b) 2 ports–no central bore, (c) 2 ports–1 central bore, (d) 3 ports–no central bore and (e) 3 ports–1 central bore. The mould flow analysis with different SEFs reflects that with straight bore SEF, problem of inactive meniscus is dominant. Both types of 2-port SEF’s flange region experiences a high impact velocity from incoming steel jet. The 3-port SEF without central bore leads to high velocities on both the flange and web region. The 3-port SEF with central bore is found to satisfy all the mould flow criteria and suggests a stable mould fluid flow.

Experimental Study of the Mold Flow Induced by a Swirling Flow Nozzle and Electromagnetic Stirring for Continuous Casting of Round Blooms

This study focuses on an experimental investigation of the fluid flow in round bloom continuous casting using a 1:3 model of the industrial casting process. A swirling flow nozzle, represented by the specific design of the RHI Magnesita GYRONOZZLE, is used to produce a swirling motion in the cylindrical mold. The test section is integrated into the Mini-LIMMCAST facility at HZDR, which is operated at room temperature using the ternary alloy GaInSn. Systematic measurements of horizontal and vertical velocity profiles are performed by means of the Ultrasound Doppler Velocimetry. The second part of the study focuses on the interaction between the flow driven by the GYRONOZZLE and concurrent electromagnetic stirring in the mold (M-EMS) by applying rotating magnetic fields (RMFs) at different magnetic flux densities. The effect of the GYRONOZZLE on the flow pattern inside the mold is examined with and without superimposed RMFs and compared to those of a standard single-port nozzle. The measurements reveal that the GYRONOZZLE induces a swirling flow in the whole mold. It is further shown that the influence of a simultaneously applied RMF is mainly restricted to the lower part of the mold since the transport of angular momentum to the top is suppressed by the jets pouring out from the GYRONOZZLE.

Study on the design and execution of a short fiber reinforced polyamide part

This article presents the stages and problems that can arise from the design to the realization of a part obtained through the process of injection. The model part used in the research is a part used in the automotive industry made on a large scale. The material from which the workpiece is made is a polymer that is part of the Polyamide class namely Polyamide 6.6 armed with short fiberglass (SGFR-PA 6.6). The fiberglass arming was made at a 30% rate, resulting in a significant increase in the mechanical characteristics of the workpiece. The validation of the flow in the injection mold was done using Moldflow Adviser™. Due to the contraction of the material, different problems of the injected parts may occur, which endanger their proper functioning. Measurements were done by using a GOM ATOS™optical scanner. The scanned part was compared with the CAD model and the deviations were observed.

Design & Analysis of Plastic Hanger Component using Mold Flow Software

Paper represents the design of HANGER which is in plastic form. In this design we use injection mould for making plastic product. In market and industries plastic demand is very high. Each and every product is made by plastic material in this world. There are various techniques for manufacturing the plastic products according to the market requirement. So as per the topic which is named as plastic advanced “HANGER” for this there is an technique which is Injection Molding machine process. This technology is belongs to making mold & manufacturing of different kind of shapes with proper accuracy. So this process is most important for manufacturing the plastic product parts by using forcing method for melt the plastic into mold cavity & then its cooling process for developed specific or can say particular plastic shape. So the requirements for making different type of plastic products we use various advance technologies like CAD/CAM/CAE. The paper defines the design and analysis of HANGER component. Basically we all know Hanger is used to hang the clothes, accessories and other ornament and any kind of things. Create a new model of Hanger that is easily movable, easily rotate, specify extra space in an common space and to fulfill current market and human being needs. So for all these techniques we use mold flow software and make a perfect 3D model of the component. This software is more powerful for simulation and analysis for a component and also locates the defect in a product. So with the help of this software, the “HANGER” can be easily moved because its size and weight.

Effect of Immersion Depth of a Swirling Flow Tundish SEN on Multiphase Flow and Heat Transfer in Mold

The effect of the immersion depth of a new swirling flow tundish SEN (Submerged Entry Nozzle) on the multiphase flow and heat transfer in a mold was studied using numerical simulation. The RSM (Reynolds Stress Model) and the VOF (Volume of Fluid) model were used to solve the steel and slag flow phenomena. The results show that the SEN immersion depth can significantly influence the steel flow near the meniscus. Specifically, an increase of the SEN immersion depth decreases the interfacial velocity, and this reduces the risk for the slag entrainment. The calculated Weber Number decreases from 0.8 to 0.2 when the SEN immersion depth increases from 15 cm to 25 cm. With a large SEN immersion depth, the steel flow velocity near the solidification front, which is below the mold level of SEN outlet, was increased. The temperature distribution has a similar distribution characteristic for different SEN immersion depths. The high temperature region is located near the solidification front. Temperature near the meniscus was slightly decreased when the SEN immersion depth was increased, due to an increased steel moving distance from the SEN outlet to the meniscus.

Scale-Adaptive Simulation of Transient Two-Phase Flow in Continuous-Casting Mold

Scale-adaptive simulation (SAS) of the transient gas–liquid two-phase flow in a laboratory-scale continuous-casting mold is presented. The main objective is to investigate the applicability of the scale-adaptive unsteady Reynolds-averaged Navier–Stokes turbulent model (URANS SAS) for predicting the transient multiscale turbulent structures in a two-phase flow. Good quantitative agreements with the experimental data and the large eddy simulation (LES) results are obtained both for the time-averaged velocity field and for the transient turbulent characteristics. The introduction of the von Karman length-scale into the turbulence-scale equation allows the SAS model to dynamically adjust to the resolved turbulent structures. The LES-like pulsating behavior of the air gas and the large-scale liquid eddy magnitudes in the unsteady regions of flow field are captured by the SAS model. The classical − 5/3 law of power spectrum density (PSD) of the axial velocity is kept properly for the single-phase turbulent flow. For two-phase flow, the decay of PSD is too steep at the high-frequency region; the predicted PSD obtained with SAS is damped stronger than that estimated by LES. The SAS model offers an attractive alternative to the existing LES approach or to the other hybrid RANS/LES models for strongly unsteady flows.

Optimization for Reducing Warpage in Injection Moulding

Injection molding is a standout technique utilized for the fabrication of thermoplastic parts in industry due to short product cycles, high part quality, good mechanical properties and low cost for large scale manufacturing. In molded case circuit breaker (MCCB), Trip-bar is one of the most critical components as safety is concerned which is manufactured by injection molding process. To get it manufactured within the specified warpage and deformities free, number of mold flow simulations is carried out using Creo-MoldFlow. The outcomes of the simulation are used to design the mold tool and the process parameters for injection molding are optimized. For process parameter optimization Taguchi based experimental design and ANOVA analysis is done. The objective of this work is to optimize the injection molding process parameters such as filling time, melt temperature and mold temperature to minimize the warpage. CAE flow simulation software is used to simulate the process and Grey Relational Analysis (GRA) is used to find out optimum process parameters.

Development of EMBr/EMS Multifunction Mold

EMBr (ElectroMagnetic Brake) and in-mold EMS (ElectroMagnetic Stirring) have been developed to control molten steel flow in a continuous casting mold. EMBr is able to stabilize the molten flow in the mold. EMBr is usually used to prevent breakout during high speed casting of medium carbon steel. In-mold EMS is effectively to improve surface quality of the cast such as interstitial free steel by forced flow of the molten steel in front of initially solidifying shell. Suitable molten flow pattern in the mold is depends on its casting condition and components. However, ordinary electromagnetic device has only one function of EMBr or EMS, so a multifunction device which can be selected EMBr or EMS in the mold is desirable. It is difficult to obtain sufficient performance both EMBr and EMS in only one electromagnetic device because the necessary structure of them is different. EMBr needs to generate large magnetic flux density by large teeth of iron core. A lot of small teeth are necessary for EMS to generate travelling magnetic field along the mold side uniformly. The structure and current applied method of the EMBr/EMS multifunction mold has been developed by numerical analysis of electromagnetic field and fluid flow dynamics. The EMBr/EMS multifunction mold has been applied to Kashima No.3 CC.

Overview of Electromagnetic Forces to Control Flow During Continuous Casting of Steel

During continuous casting of steel slabs, electromagnetic forces can be applied to help control the flow pattern in the mold, augmenting the effects of nozzle and strand geometry, casting speed, and argon injection. Specific configurations include: local, single-ruler, and double-ruler electromagnetic braking, traveling magnetic fields which actively drive flow in the upper mold, (speeding up, slowing, or stirring), and recently combinations of both systems together. Electromagnetic forces have the advantage of being changeable with casting conditions, and naturally adjust with flow variations. This gives this important flow-control tool the potential to stabilize flow in the mold, and to control molten steel velocities to lessen defects. To achieve these benefits in practice, however, requires good understanding of how the defects form, and the details of how the electromagnetic field(s) affect the transient flow. The best way to gain this understanding is by combining validated computational models with plant measurements. This paper shows recent advances using these tools to understand how different configurations affect both steady and transient flow behaviour, the formation of defects from level fluctuations, meniscus freezing, inclusion entrapment, and other mechanisms. These findings suggest promising ways to implement electromagnetic forces to lower defects to improve the process.

Online Flow Control with Mold Flow Measurements and Simultaneous EM Braking and Stirring

To obtain flow control of the molten metal in the mold where the initial solidification steps of continuous casting occur, a versatile electromagnetic actuator is required to enable both flow acceleration and stabilization to counteract different undesired flow phenomena. Various mold monitoring systems instantly give insights into the dynamics of the meniscus level, solidification status and molten steel flow characteristics during casting. An online mold flow sensor in combination with an electromagnetic actuator capable of applying time varying braking and stirring forces simultaneously, enable closed loop mold flow control with automatic handling of regular as well as sudden variations in the casting conditions in real time.A control package for the FC Mold G3, a combined two-level electromagnetic actuator with a brake in the bottom of the mold and a combined stirrer and brake in the top of the mold, reacting on varying macroscopic casting conditions has been used in steel plant production to minimize quality and operational issues. The control relies on predictions of the amount of surface defects based on experience and numerical simulations of the fluid flow. Plant quality results, collected during a year of full production, show a surface defect reduction of more than 50% with FC Mold G3 on critical ULC grades for exposed automotive body panels [1]. In the next step, real time information taken directly from process monitoring will dynamically control the FC Mold with further improved slab cleanliness and surface quality as a result.

Experimental modelling of continuous casting of steel in slab moulds using low melting liquid metals

Electromagnetic actuators are widely used in industry for contactless control of the steel flow in the continuous casting process. However, a real control of the flow structure by those actuators is a challenging task due to the lack of flow monitoring devices. Even a satisfying non real-time characterisation of the melt flow from plant measurements is missing. Beside numerical simulations, only a very few spatially and temporally limited measurements in liquid steel are available to investigate the actual action of the magnetic fields on the fluid.Therefore, model experiments with low melting point liquid metals are an important tool to investigate the flow structure and related transport processes in the mould of a continuous caster. Their advantage is the availability of a variety of measurement techniques for quantitative flow measurements. The application of the Ultrasonic-Doppler-Velocimetry (UDV) and the Contactless-Inductive-Flow-Tomography (CIFT) allows for a detailed characterization of the mould flow with a reasonable spatial and temporal resolution.In recent experiments at HZDR, the systematic study on the influence of an electromagnetic brake on the mould flow in a slab caster was continued. The measurements were carried out using a 1:2 scaled model operated with SnBi and a 1:8 scaled model operated with GaInSn, respectively. The melt surface was partly measured by a laser scanner system. In particular, the immersion depth of the submergence entry nozzle (SEN) was varied during the experiments. It became obvious that changes in the mould flow had a strong influence on the free surface of the melt, where strong perturbations can significantly impair the surface quality of the final steel strands. Moreover, effects from the “artificial” clogging of one SEN-port or the injection of Argon gas at the stopper rod were investigated.

Experimental and numerical investigation on particle-induced liquid metal flow using Lorentz force velocimetry

The dynamics of electrically non-conducting particles in liquid meal flow are of interest in a number of metallurgical processes. For instance, during continuous casting of steel, proper removal of slag particles interacting with mold flow is crucial for the quality of the product. However, as such flows are very complex, analyzing single effects are almost impossible. Therefore, we investigate experimentally a simplified configuration where spherical particles of known size are pulled in the vertical direction with a controlled speed at a given position through a liquid metal column initially at rest. As a test melt we use the alloy GaInSn in eutectic composition which is liquid at room temperature. The displacement flow induced by the particle movement is measured using Lorentz force velocimetry. This method is based on recording the flow-induced force acting on an externally arranged permanent magnet. In the present paper we extend earlier work by analyzing not only the drag force in the direction of the particle movement but also the lift force acting in the horizontal direction. Moreover, we use an improved signal processing routine that allows us to perform measurements at higher particle Reynolds numbers. The experimental results are in both quantitatively and qualitatively agreement with the predictions of numerical simulations using the commercial code ANSYS/FLUENT.