Continuous casting simulation problem
 

Dear friends,

I am using FLUENT for simulating a continuous casting problem. In fact, I want to repeat the simulation given in the following paper at the first stage, without considering the segregation problem(just flow and solidification):

http://www.springerlink.com/content/u159222514283281/

The simulated length of caster is 3m, with mold length of .5m, mold diameter of 11.5cm, nozzle diameter of 3cm, and casting speed of .01m/s. I am using a 2D mesh as the casting part is a round billet.

I have modeled the case in FLUENT, but there are some problems:

1- The steady solver doesn't work at all, it diverges quickly. I have played with initial condition and UDFs, but I couldn't fix it. Note that the paper I mentioned solved the steady equations.

2- The unsteady solver works fine, but the system does not become steady as expected. I continues cooling and solidifying as the simulation runs. This is not correct, as I guess at about the lenght 2.5-3m the complete solidification should occur.

3- I don't know how to set the outlet boundary condition to what the paper says, i.e. letting all normal gradients to zero. I used a "velocity inlet" boundary condition with x-component velocity set to casting speed.

I had played a lot with problem changing many parameters. But there were no success!

Do you have any idea to fix the problem? And, how should I set the zero-gradient outlet boundary condition?

And, does anyone has an example of similar system in FLUENT which can send it to me?

Very thanks.

Luke Christ
luke.christ23@gmail.com

Hi
 

Dear Luke Christ,

I am also trying to model the similar problem (segregation during Continuous casting). Is it possible to model the paper http://www.springerlink.com/content/u159222514283281/ using FLUENT.

I have just started my work, can you please share your experience in modeling solidification in continuous casting using FLUENT.

Thanks,

Niranjan Reddy Ch.

Segregation in continuous casting
 

Hi

Just a quick question, have any one ever used ANSYS fluent for modeling segregation in continuous casting?? I'll be appreciate if any one help me with the problem... Here is my E-mail : tuv989@gmail.com

Thanks

Continuous casting simulation with Ansys Fluent
 

Hello sir,

Kindly any one of above reply if you have solved this problem. I will be very thankful to you.

Trying to validate the same paper. 4th person in the queue:confused:doubting whether it is possible to validate those results or not. It will be great if anyone can atleast reply for sure whether the results has been successfully validated or not.

Finally??
 

I am involved in a similar project. Did you finally figure it out ?

Hello sir,
I also encountered the same problem recently. I am not sure if I can solve the segregation phenomenon with fluent, because I am a beginner. If possible, can you send me a copy of your segregation materials or tutorials, I am very grateful! Here is my E-mail : qinhuaxie095@gmail.com
Best wishes！