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Numerical simulation of fluid flow and free surface fluctuations during wheel and belt casting process

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Abstract

The unstable fluid flow and severe free surface fluctuations in the wheel and belt caster can affect the quality of the cast bar. The lower level height tends to entrap inclusions in the molten metal. On the other hand, the higher level height makes the production process more dangerous due to the overflow of high temperature fluid from the mold. A computational model of the molten metal pouring process was established. The transient fluid flow and free surface fluctuations behavior were calculated using the three-dimensional large eddy simulation model and the volume of fluid model. The results show that the flow velocity of the main jet gradually decreases under the influence of the low kinetic energy fluid in the mold. There is an obvious oscillation in the tail of the jet, while the flow field is asymmetric in space. The jet is closer to the inside radius side due to the Coanda effect, and there is a recirculation zone on the inside radius and the outside radius respectively, according to the 10 s time-averaged results. Compared with the industrial observation and simulation results, the shape of the free surface is a wave that varies with time. In addition, the free surface height is lowest and the flow velocity is highest in the region near the jet.

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Acknowledgements

This work was financially supported by Innovative Research Groups Project of the Natural Science Foundation of Hebei Province (No. E2021203011) and Central Government Guides Local Science and Technology Development Fund Projects (No. 206Z1601G).

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Authors and Affiliations

  1. National Engineering Research Center for Equipment and Technology of Cold Strip Rolling, Yanshan University, Qinhuangdao, 066004, Hebei, China

    Kun Gao & Yan Peng

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  1. Kun Gao
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  2. Yan Peng
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Correspondence to Yan Peng.

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Gao, K., Peng, Y. Numerical simulation of fluid flow and free surface fluctuations during wheel and belt casting process. J. Iron Steel Res. Int. 31, 1117–1126 (2024). https://doi.org/10.1007/s42243-023-01116-y

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  • DOI: https://doi.org/10.1007/s42243-023-01116-y

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