E. Hepp, P. Bernbeck, W. Schäfer, MAGMA Gießereitechnologie GmbH, Aachen
D. Senk, S. Stratemeier, Institut für Eisenhüttenkunde IEHK der RWTH Aachen University, Aachen
Casting process simulation programs are designed to offer the engineer a powerful tool for a virtual optimisation of casting processes. Due to the complexity and variety of physical phenomena driving the continuous casting process of steels, the requirements for an integrated simulation tool are challenging. In a cooperative effort, the Department of Ferrous Metallurgy (IEHK), RWTH Aachen University and a developer of professional process simulation software (MAGMA) have joined forces with theoretical and practical expertise. In this paper, two aspects of continuous casting modelling will be discussed: First, the prediction of the liquid pool depth and second, possible causes of crack formation during the entire process. In both cases primary process parameters and required boundary conditions for a comprehensive simulation of the entire process route are discussed. The results of thermal and mechanical calculations are presented. The evaluation of results shows the strong influence of process parameters like casting speed and spray cooling on the depth of the liquid pool. Analyzing crack formation, special focus is put on the mechanical properties at high temperature as an input variable. The discussed developments will be part of an integrated and practical tool for the engineer to optimise his processes and his productivity.
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