电磁场下钢锭连铸凝固传输行为耦合数值模拟
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摘要
在钢锭连铸过程中,合金熔体的传热、传质和熔体流动是凝固过程中重要的传输现象,这些传输行为决定着铸锭的结晶质量。同时凝固过程各个传输现象之间彼此紧密关联并相互影响,加入电磁场后会使这种耦合传输现象更加复杂。因此,研究电磁连铸凝固过程中耦合传输现象,揭示电磁场作用下钢凝固传输行为的规律,可为优化工艺参数提高铸件质量提供依据,具有重要的研究意义。
本文以理论建模和计算机模拟为研究手段,基于本课题组已有的研究工作,将凝固传热、传质及动量传输的耦合传输统一模型应用到电磁连铸过程,以实现钢锭连铸系统电磁场和凝固传输的耦合传输数值模拟。为此,本论文进行了如下研究工作:
建立了在电磁场与重力场共同作用下,连铸钢锭相对实验室静止坐标系以一定的抽拉速度V0运动的电磁凝固过程传热、传质与动量传输的耦合数学模型与数值计算方法。采用FORTRAN语言编制了电磁连铸的凝固传输计算程序,实现了电磁连铸凝固传输的耦合数值模拟。
采用ANSYS软件分析计算了本论文钢锭电磁连铸过程所施加的电磁场,包括不同强度的横向静磁场和不同形式的行波电磁场。利用本试验室自行研发的FORTRAN有限元/有限差数据格式转换技术,将ANSYS计算的基于有限元分析的电磁场的计算结果转换为凝固传输计算程序可读的有限差格式的数据。
将电磁场计算结果耦合到连铸凝固传输计算程序中,初步实现了钢锭连铸凝固传输与电磁场的耦合数值模拟。模拟结果包括:液相流场、固相分数场、洛仑兹力场、温度场和成分场等。进行了无磁场仅重力场作用下钢锭连铸凝固传输的数值计算,表明本文所建立的相对静止坐标系运动条件下电磁连铸系统凝固传输耦合模型及数值计算方法是可行的。进行了初步的静磁场/行波电磁场和重力场共同作用下的连铸钢锭凝固传输行为的耦合数值模拟计算,分析了不同强度的磁场对液相流场的抑制作用,考察了不同极对数的行波电磁场对连铸钢锭凝固过程的影响。
The solidification transport phenomena (STP), i.e. heat, mass and momentum transfer in alloy solidification systems are very important and complicated due to the strong coupling among them. When an electromagnetic filed (EMF) is applied to the solidifying system, that coupled correlations will becom even more complicated. Research on the coupled solidification transport phenomena and the influence of EMF on the solidified process of steel ingot can give advice to improve the quality of ingots, and is very meaningful.
The aim of the present thesis is to establish an EM-coupled continuum model for STP in the electromagnetic continuous casting (CC) processes of steel ingots based on the previous work of our research group, using the method of theoretical modeling and computer simulation. The main work inclued:
The mathematical model in a continuum form and the corresponding numerical formula for the electromagnetic STP of the steel ingot in EMC process are established, which is under both gravity and electromagnetic fields and with a movement velocity V0 relatively to the static lab coordinate. Computer codes in FORTRAN language is developed for numerical simulation of the EMC-STP processes.
The ANSYS software is explored to analyze the static and traveling magnetic fileds applied to the EMC system. Conversion of the EMF-data from ANSYS finite element method (FEM) format, included the B vector field, induction current density, Joule heat and so on, to finite different method (FDM) format is performed using our own data processing FORTRAN program.
Coupling the conversed EMF-data to the STP simulation program, preliminary computational results, including the liquid flow velocity, temperature filed, solid volume fraction filed, Lorentz force filed and so on in EM-continuous casting processes of steel ingots, indicate that the present computer modeling is successful.
The coupled simulation results for the CC-STP behaviors under different static and traveling EMFs show that, application of a static magnetic field to the steel ingot continuous casting process can effectively suppress the bulk liquid flow, and the braking effects enhance with the increase of the magnetic field’s intensity; the application of traveling magnetic field can obviously change the liquid flow patterns.
本文以理论建模和计算机模拟为研究手段,基于本课题组已有的研究工作,将凝固传热、传质及动量传输的耦合传输统一模型应用到电磁连铸过程,以实现钢锭连铸系统电磁场和凝固传输的耦合传输数值模拟。为此,本论文进行了如下研究工作:
建立了在电磁场与重力场共同作用下,连铸钢锭相对实验室静止坐标系以一定的抽拉速度V0运动的电磁凝固过程传热、传质与动量传输的耦合数学模型与数值计算方法。采用FORTRAN语言编制了电磁连铸的凝固传输计算程序,实现了电磁连铸凝固传输的耦合数值模拟。
采用ANSYS软件分析计算了本论文钢锭电磁连铸过程所施加的电磁场,包括不同强度的横向静磁场和不同形式的行波电磁场。利用本试验室自行研发的FORTRAN有限元/有限差数据格式转换技术,将ANSYS计算的基于有限元分析的电磁场的计算结果转换为凝固传输计算程序可读的有限差格式的数据。
将电磁场计算结果耦合到连铸凝固传输计算程序中,初步实现了钢锭连铸凝固传输与电磁场的耦合数值模拟。模拟结果包括:液相流场、固相分数场、洛仑兹力场、温度场和成分场等。进行了无磁场仅重力场作用下钢锭连铸凝固传输的数值计算,表明本文所建立的相对静止坐标系运动条件下电磁连铸系统凝固传输耦合模型及数值计算方法是可行的。进行了初步的静磁场/行波电磁场和重力场共同作用下的连铸钢锭凝固传输行为的耦合数值模拟计算,分析了不同强度的磁场对液相流场的抑制作用,考察了不同极对数的行波电磁场对连铸钢锭凝固过程的影响。
The solidification transport phenomena (STP), i.e. heat, mass and momentum transfer in alloy solidification systems are very important and complicated due to the strong coupling among them. When an electromagnetic filed (EMF) is applied to the solidifying system, that coupled correlations will becom even more complicated. Research on the coupled solidification transport phenomena and the influence of EMF on the solidified process of steel ingot can give advice to improve the quality of ingots, and is very meaningful.
The aim of the present thesis is to establish an EM-coupled continuum model for STP in the electromagnetic continuous casting (CC) processes of steel ingots based on the previous work of our research group, using the method of theoretical modeling and computer simulation. The main work inclued:
The mathematical model in a continuum form and the corresponding numerical formula for the electromagnetic STP of the steel ingot in EMC process are established, which is under both gravity and electromagnetic fields and with a movement velocity V0 relatively to the static lab coordinate. Computer codes in FORTRAN language is developed for numerical simulation of the EMC-STP processes.
The ANSYS software is explored to analyze the static and traveling magnetic fileds applied to the EMC system. Conversion of the EMF-data from ANSYS finite element method (FEM) format, included the B vector field, induction current density, Joule heat and so on, to finite different method (FDM) format is performed using our own data processing FORTRAN program.
Coupling the conversed EMF-data to the STP simulation program, preliminary computational results, including the liquid flow velocity, temperature filed, solid volume fraction filed, Lorentz force filed and so on in EM-continuous casting processes of steel ingots, indicate that the present computer modeling is successful.
The coupled simulation results for the CC-STP behaviors under different static and traveling EMFs show that, application of a static magnetic field to the steel ingot continuous casting process can effectively suppress the bulk liquid flow, and the braking effects enhance with the increase of the magnetic field’s intensity; the application of traveling magnetic field can obviously change the liquid flow patterns.
引文
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2 S.Asai. Recent Development and Prospect of Electromagnetic Processing of Material Science and Technology of Advanced Materials. 2000,(1): 191~200
3毛丽贺.电磁场下钛合金叶片定向凝固传输行为计算机模拟.哈尔滨工业大学硕士学位论文,2003:5
4李双明,李金山,郝启堂等.金属熔体的电磁近终成形技术.中国机械工程. 2000,11(1-2):73~76
5 Vives C. Electromagnetic Refining of Aluminum Alloys by the CREM Process: Part I.Working Principle and Metallurgical Results[J]. Metall. Trans. B. 1989, 20B(10):623~629
6邓康,任忠鸣,蒋国昌.软接触电磁连铸的数值模拟和实验分析.金属学报. 1999, 35(10):112~1114
7王宏明,任忠鸣,雷作胜等.钢的软接触电磁连铸技术.铸造技术. Sep.2005, 26(9):782~784
8 S.N.TEWARI, RAJESH SHAN, Hui SONG. Effect of Magnetic Field on the Microstructure and Macrosegregation in Directionally Solidfied Pb-Sn Alloys. Metallurigical and Materials Transactions A. 1994, 25A:1535~1544
9 Eiichi Takeuch. Applying MHD Technology to the Continuous Casting of Steel Slab. JOM. MAY. 1995:42~45
10 Yun-Seong HWANG et al. Numerical Analysis of the Influences of Operational Parameters on the Fluid Flow and Meniscus Shape in Slab Caster with EMBR. ISIJ International. 1997,37(7):659~667
11张宏丽,王恩刚等.电磁搅拌提高铸坯等轴晶比率的数值模拟.东北大学学报(自然科学版). 2001,22(5):535~538
12苏彦庆,毕维生,黄俊勇,张铁军.电磁铸造移动磁场发生器磁场分布规律及其作用分析.特种铸造及有色合金. 2005, 25(1):10~12
13张铁军.大型薄壁铝合金件移动磁场铸造充型过程基础研究.哈尔滨工业大学博士学位论文. 2003:11~17
14张宏丽等.线性电磁搅拌器电磁场分布的数值模拟.东北大学学报.2002,23(9):352~354
15麻永林,宿国栋,黄海娥,刘洪潇,胡慧明,王国栋.板坯行波电磁搅拌器磁场分布规律的实验研究. Journal of Baotou University of Iron and Steel Technology. 2005, 24(3):224~226
16久保田淳等.用移动磁场控制板坯连铸结晶器内的钢液流动重钢技术. 2002,2:27~33
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