Steel Electromagnetic Casting Of Complex Sensor System And The Electromagnetic Field Of The Finite Element Method Calculation

The density of steel is 1.7 times as large as that of aluminum and electrical conductivity is 1/6 of it. According to this fact, it is approximately calculated that about 22000A current of steel EMC is needed, namely about 4.4 times of that of aluminum EMC for traditional inductor. Such large current can only be given by special power supply. So three methods intensif~ring magnetic induction during EMC processing were investigated, and a new technology of steel EMC with compound inductors was brought forward.Based on differences of the interfaces between compound coil and inductor coil, the design of single, double or three compound interface inductors was posed, their physical models were analyzed and evaluated by using the mirror image theories on magnetic field.The magnetic field distribute of compound inductors was measured and it was found the magnetic induction intensity of single compound inductor intensified 1.85 times of that of traditional EMC inductor, double compound inductor intensified 2.26 and three intensified 2.64. The results showed the technology of compound inductors is an optimized method to meet the necessity of supporting half-suspended liquid column of steel. The optimized design parameters were as follows: the height of compound coil h=l 5棐2Omm, the depth of compound coil extended into inductor coil d=O桽mm, the gap between compound coil and inductor coil 8 ~2mm.Effects of the gap 8, the material orientation of compound coils, inductor coil turns as well as current on intensity and distribute of magnetic field were studied.In order to study it, the liquid forming of Sn was investigated and the conclusion was the height of Sn liquid column with compound inductors was higher and under the same power conditions, the width was smaller compared to traditional inductor.The numerical calculation of magnetic field including magnetic materials was primarily researched. The finite element mathematical model was set up and the calculation results based on it were accordance with the experiments?In this paper, the design difficulties of compound inductors were also pointed out. Any way, it is believed that the compound inductors will be developed to cast steel successfully in future.