Numerical Simulation Of Liquid Aluminum Leakage In Metal Casting Process

Based on the big security issue of violent explosion of high-temperature molten aluminum in contact with water under certain conditions,in the current aluminum electrolysis industrial production process.And there are no prevention and early warning technology and equipment of explosion at present.The article numerically simulates the leakage and runoff that occurs during the liquid aluminum pouring,and aims to provide technical support for the early warning equipment of explosion,and therefor realize the safe production of aluminum electrolysis industry.Taking the liquid aluminum pouring process in the foundry of Taiyuan Eastern Aluminum Materials Co.Ltd.as the prototype,the 3D geometric model was constructed by ICEM,and the leakage process of the liquid aluminum pouring was numerically simulated by using Fluent software.Firstly,through the simulation calculation of VOF and other models,the flow field and temperature field of liquid aluminum in the chute during the liquid aluminum pouring process are obtained,under different mixing furnace outlet radius and mixing furnace liquid aluminum height.The mass flow rate at the outlet of the mixing furnace was increased from 10.77 kg/s(R=0.04 m,H=1.0 m)to 81.04 kg/s(R=0.08 m,H=1.3 m).Even if the outlet of the mixing furnace increases due to accidents(R=0.06m,R=0.08m),the liquid aluminum pouring process does not cause an overflow leakage accident;Compared with the initial temperature of 750?,the flow of high-temperature molten aluminum in the chute,the temperature is reduced by a minimum of 3?(R=0.08 m,H=1.3 m),the highest is reduced by 40?(R=0.04 m,H=1.0 m).Based on the calculation results of the flow field and temperature field in the liquid aluminum pouring process,the liquid aluminum overflow leakage simulation was carried out.The liquid aluminum is filled in the long chute and the liquid aluminum outlet of the chute is closed to cause the overflow leakage of liquid aluminum during the pouring process of the liquid aluminum.the overflow leakage form of liquid aluminum is that the liquid aluminum at the left of the long chute starts to leak first,and the liquid aluminum in the long chute surged to the right through the form of "wave"which due to the impact of the liquid aluminum flowing from the short chute.And the right of the long chute began to leak gradually.The different leakage time of the liquid aluminum at the left and right of the long chute causes the liquid aluminum of leakage on the ground to exhibit a "long strip shape" distribution,which the left of strip is width and the right of strip is narrow.The diffuse area per unit time of the leaked and liquid aluminum on the ground was obtained,under different conditions.The diffused area per unit time increased from 0.34 m2/s(R=0.04 m,H=1.0 m)to 0.68 m2/s(R=0.08 m,H=1.3m).The leakage per unit time increases with the height of the liquid aluminum when the outlet radius of the mixing furnace is the same.Under different conditions,the leakage per unit time increased from 3.44 kg/s(R=0.04,H=1.0)to 66.97 kg/s(R=0.08 m,H=1.3 m).