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luke.christ April 3, 2009 05:54

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):

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

creddy_trddc August 17, 2011 07:23

Dear Luke Christ,

I am also trying to model the similar problem (segregation during Continuous casting). Is it possible to model the paper using FLUENT.

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


Niranjan Reddy Ch.

M.Panther1989 May 9, 2013 13:17

Segregation in continuous casting

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 :


Yuvaraj June 20, 2015 10:31

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.

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