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  • Author: K. Miłkowska-Piszczek x
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Open access

K. Miłkowska-Piszczek and J. Falkus

Abstract

This paper presents development and the application of a numerical model of the continuous steel casting process to optimise the strand solidification area. The design of the numerical model of the steel continuous casting process was presented and which was developed based on the actual dimensions of the slab continuous casting machine in ArcelorMittal Poland Unit in Kraków. The S235 steel grade and the cast strand format of 220×1280 mm were selected for the tests. Three strand casting speeds were analysed: 0.6, 0.8 and 1 m min-1. An algorithm was presented, allowing the calculation of the heat transfer coefficient values for the secondary cooling zone. In order to verify the results of numerical simulations, additional temperature measurements of the strand surface within the secondary cooling chamber were made. The ProCAST software was used to construct the numerical model of continuous casting of steel.

Open access

K. Miłkowska-Piszczek

Abstract

The values of thermophysical properties obtained from the experimental research, and those that were calculated with thermodynamic databases, are crucial parameters which were used in the numerical modelling of the steel solidification process. This paper presents the results of research on the impact of specific heat and enthalpy, along with the method of their implementation, on temperature distribution in the primary cooling zone in the continuous steel casting process. A cast slab – with dimensions of 1100 mm and 220 mm and a S235 steel grade – was analysed. A mould with a submerged entry nozzle (SEN), based on the actual dimensions of the slab continuous casting machine, was implemented. The research problem was solved with the finite element method using the ProCAST software package. Simulations were conducted using the “THERMAL + FLOW” module.

Open access

K. Milkowska-Piszczek and M. Korolczuk-Hejnak

Abstract

The numerical modelling of casting processes is based on complex software packages, which most often use the finite element method. But the degree of complexity of the applied model may cause an occurrence of numerical errors. These errors may be generated both by an incorrect finite element mesh and by the use of incorrect material characteristics. The ProCAST numerical software package was used for numerical calculations. A 3D model was developed on the basis of the process parameters of an actual continuous steel casting process. The temperature distribution of a solidifying strand, with dimensions of 220x1100mm, was analysed for two steel grades: F320 and S235. A series of numerical simulations were performed where the influence of the applied viscosity values on the solidifying strand temperature distribution was presented. Viscosity values from rheological examinations that were performed with an FRS1600 high-temperature rheometer were used in the numerical simulations of the CC process. The aforementioned rotational measurements were carried out for the F320 and S235 steels in the liquid and in the semi-solid statesto examine the influence of temperature on the viscosity value changes obtained. A concentric cylinder systems working in accordance with Searle’s method was used for the measurements. Numerical calculations that were based on the viscosity values from the CompuTherm LLC, thermodynamic database were compared with one other in the project. The calculated temperature distribution of the solidifying CC strand was verified on the basis of a database that was created during measurements which were conducted in industrial conditions.

Open access

M. Rywotycki, K. Miłkowska-Piszczek and L. Trębacz

Identification of the Boundary Conditions in the Continuous Casting of Steel

The results of investigations relating the determination of thermal boundary conditions for continuous casting of steel were presented in the paper. The slab of dimensions 1100 mm x 220 mm was analyzed. In numerical calculations two models were compared. The first was the simple one and it used average heat transfer coefficient in both cooling zones. The second one used complex models in primary and secondary cooling zones. The presented models were verified on basing on an industrial data base. The problem was solved by the finite element method and the commercial numerical packet ProCAST.

Open access

K. Konopka, K. Miłkowska-Piszczek, L. Trębacz and J. Falkus

Abstract

The study presents the findings of research concerning the possibilities for application of parallel processing in order to reduce the computing time of numerical simulations of the steel continuous casting process. The computing efficiency for a CCS model covering the mould and a strand fragment was analysed. The calculations were performed with the ProCAST software package using the finite element method. Two computing environments were used: the PL-Grid infrastructure and cloud computing platform.

Open access

K. Miłkowska-Piszczek, M. Rywotycki, J. Falkus and K. Konopka

Abstract

This paper presents the findings of research conducted concerning the determination of thermal boundary conditions for the steel continuous casting process within the primary cooling zone. A cast slab - with dimensions of 1100 mm×220 mm - was analysed, and models described in references were compared with the authors’ model. The presented models were verified on the basis of an industrial database. The research problem was solved with the finite element method using the ProCAST software package.

Open access

J. Falkus and K. Miłkowska-Piszczek

This paper presents a strategy of the cooling parameters selection in the process of continuous steel casting. Industrial tests were performed at a slab casting machine at the Arcelor Mittal Poland Unit in Krakow. The tests covered 55 heats for 7 various steel grades. Based on the existing casting technology a numerical model of the continuous steel casting process was formulated. The numerical calculations were performed for three casting speeds - 0.6, 0.8 and 1 m min-1. An algorithm was presented that allows us to compute the values of the heat transfer coefficients for the secondary cooling zone. The correctness of the cooling parameter strategy was evaluated by inspecting the shell thickness, the length of the liquid core and the strand surface temperature. The ProCAST software package was used to construct the numerical model of continuous casting of steel.

Open access

M. Rywotycki, Z. Malinowski, K. Miłkowska-Piszczek, A. Gołdasz and B. Hadała

Abstract

The paper presents the results of research concerning the influence of radiative heat transfer on the strand and mould interface. The four models for determining the heat transfer boundary conditions within the primary cooling zone for the continuous casting process of steel have been presented. A cast slab - with dimensions of 1280×220 mm - has been analysed. Models describing the heat transfer by radiation have been specified and applied in the numerical calculations. The problem has been solved by applying the finite element method and the self-developed software. The simulation results, along with their analysis, have been presented. The developed models have been verified based on the data obtained from the measurements at the industrial facility.

Open access

M. Rywotycki, Z. Malinowski, J. Falkus, K. Sołek, A. Szajding and K. Miłkowska-Piszczek

In technological process of steel industry heat transfer is a very important factor. Heat transfer plays an essential role especially in rolling and forging processes. Heat flux between a tool and work piece is a function of temperature, pressure and time. A methodology for the determination of the heat transfer at solid to solid interface has been developed. It involves physical experiment and numerical methods. The first one requires measurements of the temperature variations at specified points in the two samples brought into contact. Samples made of C45 and NC6 steels have been employed in physical experiment. One of the samples was heated to an initial temperature of: 800°C, 1000°C and 1100°C. The second sample has been kept at room temperature. The numerical part makes use of the inverse method for calculating the heat flux and at the interface. The method involves the temperature field simulation in the axially symmetrical samples. The objective function is bulled up as a dimensionless error norm between measured and computed temperatures. The variable metric method is employed in the objective function minimization. The heat transfer coefficient variation in time at the boundary surface is approximated by cubic spline functions.

The influence of pressure and temperature on the heat flux has been analysed. The problem has been solved by applying the inverse procedure and finite element method for the temperature field simulations. The self-developed software has been used. The simulation results, along with their analysis, have been presented.