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Large Eddy Simulations of the Effects of EMBr and SEN Submergence Depth on Turbulent Flow in the Mold Region of a Steel Caster

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Abstract

Transient turbulent flow in the mold region during continuous casting of steel is related to many quality problems, such as surface defects and slag entrainment. This work applies an efficient multi-GPU based code, CUFlow, to perform large eddy simulations (LES) of the turbulent flow in a domain that includes the slide gate, SEN, and mold region. The computations were first validated by comparing the predicted surface velocity with plant measurements. Then, seven LES simulations were conducted to study the effects of casting speed, electromagnetic braking (EMBr) field strength, and submerged entry nozzle (SEN) depth on the transient flow. The results show that EMBr has an important influence on flow inside the SEN, in addition to flow in the mold. With EMBr, an “M-shaped” flow profile is seen inside the SEN. The swirling flow behavior in the SEN and ports is more symmetrical at high casting speed and with higher EMBr strength. The position of the SEN ports relative to the peak magnetic field affects the EMBr performance. The results confirm and quantify how applying EMBr greatly lowers both the magnitude and turbulent variations of the surface velocity and level profile.

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Acknowledgments

The authors thank the financial supports from the National Science Foundation (Grant No. CMMI 11-30882) and the Continuous Casting Consortium, Univ. of Illinois at Urbana–Champaign. We also thank Baosteel, Shanghai, P. R. China for providing the measurements and corresponding casting conditions. This research is also part of the Blue Waters sustained-petascale computing project, which is supported by the National Science Foundation (awards OCI-0725070 and ACI-1238993) and the State of Illinois. Blue Waters is a joint effort of the University of Illinois at Urbana–Champaign and its National Center for Supercomputing Applications. The authors also thank NVIDIA Hardware Grant Program for providing the GPUs for an in-house workstation.

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Author notes

  1. Brian G. Thomas (C.J. Gauthier Professor of Mechanical Engineering, Professor of Mechanical Engineering)

    Present address: Department of Mechanical Engineering, Colorado School of Mines, 1610 Illinois Street, Golden, CO, 80401, USA

Authors and Affiliations

  1. Department of Mechanical Science and Engineering, The University of Illinois at Urbana–Champaign, 1206 West Green Street (MC-244), Urbana, IL, 61801, USA

    Kai Jin (Graduate Student and Research Assistant), Surya P. Vanka (Research Professor, Professor Emeritus) & Brian G. Thomas (C.J. Gauthier Professor of Mechanical Engineering, Professor of Mechanical Engineering)

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  1. Kai Jin
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  2. Surya P. Vanka
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Correspondence to Brian G. Thomas.

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Manuscript submitted July 1, 2016.

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Jin, K., Vanka, S.P. & Thomas, B.G. Large Eddy Simulations of the Effects of EMBr and SEN Submergence Depth on Turbulent Flow in the Mold Region of a Steel Caster. Metall Mater Trans B 48, 162–178 (2017). https://doi.org/10.1007/s11663-016-0801-z

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