Numerical Study of Solidification and Thermal-Mechanical Behaviors in a Continuous Caster
Abstract
Solidification and stress numerical models were developed in order to predict flow, shell thickness, and deformation of the shell within the mold. An investigation of temperature dependent material properties (TDMP) determined that temperature dependent (TD) viscosity has the most significant impact on flow and solidification (F&S). A steady-state (SS) F&S model validated simulated results to be within 8% of breakout shell measurements (BSM) provided by an industrial collaborator (IC). A transient F&S case replicating the casting speed and superheat change that occurred before the breakout condition was validated to be within 10% of BSM. A carbon percentage F&S investigation of 4 steels showed that shell growth increased with lower carbon percentages primarily because of changes in mushy zone (MZ) range and TD viscosity. A 2D simplification presented by Koric and Thomas for shell thickness and stress was validated to be within 1%, and 13%, respectively. The newly validated perfectly-plastic (PP) and visco-plastic (VP)stress-strain relations were then applied to a 3D portion of the shell within the mold to analyze stress and deformation. The VP model in comparison to the PP model showed higher amounts of stress but lower amounts of displacement because of the incorporation of more realistic flow and creep strains. The shell at lower casting speeds contracts more inwards because of bending stresses therefore producing larger air gap formation. Lastly, deformation within the shell of the 4 carbon percentage solidification study were compared, and results showed a (Narrow-Face) NF taper ranging from 2mm to 5mm.
Degree
M.Sc.
Advisors
Zhou, Purdue University.
Subject Area
Physics|High Temperature Physics|Materials science|Mathematics|Mechanics|Thermodynamics
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