Numerical Simulation Of Ingot Filling Process With Liquid Slag

During the filling process of steel ingots,surface tension,inlet velocity,and slag layer thickness all have a certain impact on slag and gas entrapment.Moderate slag and gas entrapment can purify molten steel to a certain extent,while excessive slag and gas entrapment can cause significant quality defects in the castings to be obtained.The traditional filling process uses solid slag,and this article uses liquid slag for filling.Through a series of calculations and data review,it is found that the results obtained from liquid slag are consistent with those obtained from solid slag.This article aims to address this issue by changing the process parameters during the filling process,simulating the filling process,and obtaining appropriate process parameters to meet on-site needs.This article adopts numerical simulation methods and takes 25 t circular electrode ingots as the research object.by establishing a mathematical model of circular electrode ingots and using open-source software Open FOAM and FLUENT for numerical simulation,the fluid flow behavior in steel ingots under different process parameters was first studied.Comparative analysis was conducted on the effects of inlet velocities(0.6m/s,1.3m/s,2.3m/s),slag layer thickness(80mm,230 mm,380mm),and surface tension(1.1N/m,1.35N/m,1.6N/m)on the flow field;Secondly,the impact of inlet velocities of 1.3m/s and 2.3m/s on heat transfer was clarified And the influence of different speeds on solidification was compared and analyzed,providing theoretical guidance for the industrialization of the filling process.Through research,the following conclusions were drawn:The free surface fluctuation of steel slag mixture and air in the determined time was studied at different mold filling speeds and mold filling slag layer thickness.Based on this,it was concluded that 1.3m/s and 80mm-230 mm slag layer thickness were the optimal scheme.Determine other process parameters at the filling speed of 0.6m/s,1.3m/s,2.3m/s at zero time,intercept the cloud diagram of the volume fraction of liquid slag and air for 6 minutes,and make a line chart diagram.Through analysis,1.3m/s is the best filling speed.In the case of surface tension of 1.1N/m,1.35N/m and 1.6N/m,the volume fraction nephogram of liquid slag and air is selected when the speed is 1.3m/s and the slag layer thickness is 80 mm,and the line chart chart of three cases when the filling time is 12 minutes is analyzed,and the simulation conclusion that 1.35N/m is the optimal surface tension is obtained.The filling speeds of 1.3m/s and 2.3m/s simulate the change of temperature field with time before the completion of mold filling.The isotherm of the two-phase zone,liquid zone and solid zone of the 1.3m/s filling speed tends to be more straight,the area of the solidification zone and two-phase zone is more stable,and the filling speed of 1.3m/s is more consistent with the actual situation.After analyzing the filling condition of two-dimensional model and overall model,quarter model and overall model,it is obtained that this simulation needs to use the overall model for simulation,so as to obtain simulation data with small error.