| This study takes the consumable electrode,slag bath,and ingot as investigated objects.Mathematical models is established based on the convection thermal transfer equation of the slag bath,the thermal conduction equation of the ingot,and the melt flowing equation,meanwhile the appropriate electromagnetic field,thermal boundary conditions are applied.The numerical simulation and experimentally study on electroslag smelting casting of fixed consumable electrode filling method are performed by using large finite element analysis software ANSYS.A 400×70×300 plate-shaped ingot was cast with a fixed consumable electrode filling method.Based on the vertical relationship between the dendrite growth direction and the slag and metal interface,a shape of plate-shaped ingot was obtained during electroslag remelting process in the metal pool.It is found that the longitudinal width of the ingot is semi-elliptical,the depth of the metal pool at the center of the mobile consumable electrode is greater than that of the fixed consumable electrode;the shape of the metal pool is inverted hump-shaped,the metal pool corresponding to mobile consumable electrode has a higher hump.According to experimental conditions,numerical simulation is performed on the shape of metal pool of electroslag casting of the consumable electrode filling method in stable stage.The simulation results are compared with the experimental results and it is found that the two are basically consistent,indicating that the numerical simulation method can be used for the simulation on the casting process of fixed consumable electrode filling method.By using the numerical simulation method for the shape of metal pool of electroslag casting of the consumable electrode filling method in stable stage,numerical simulation is performed on the forming property of ingot casting in the 400×70×300 casting size of fixed consumable electrode filling method and the filling channel of metal melt between two electrodes.The simulation results show that when the current density is greater than or equal to 0.7A/mm~2,the electrode spacing is less than or equal to 0.09 m,and the electrode thickness is greater than or equal to 0.04 m,the formability of the ingot is good,so the ingot surface between the mobile consumable electrode and the fixed consumable electrode is smooth and complete;when the current density is greater than or equal to 0.5 A/mm~2,the electrode spacing is less than or equal to 0.015m,and the electrode thickness is greater than or equal to0.035m,the two metal pools are connected and the sectional area of channel is increased with the increase of current density and the cross-sectional area of the consumable electrode. |
