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Integrated multiscale simulation of continuous casting of steel

This work copes with a simulation system for modeling of steady-state and transient temperature, velocity, and concentration fields on micro and macro level in continuously cast steel strand (billet, slab, bloom) as a function of the process parameters. The numerical solution of coupled partial differential equations is based on recently developed meshless technology, involving collocation with radial basis functions. The system is designed for estimation of influence of process parameters on strand conditions and development of casting of new materials. The options of simulation system, which enable the technologist automatic setup of process parameters, are described. The regulation coefficients of the casting machine control system can be calculated based on this system. Regulation coefficients are used for compensation of the changes of process parameters that are difficult to control (casting temperature, temperature of cooling water, heat transfer in the mold) with the easily controlled parameters (coolant water flow, casting speed) in such way that the surface temperature and liquid pool depth remain invariant. The on-line and off-line sub-modules of the system are elaborated. The on-line module helps the technologist in monitoring of the status of the main process parameters and safety related issues. The off-line post-processing module is based on the simulation system and real process parameters data base, and helps the technologists in estimation of the reasons for possible casting defects and suppression of them. The implementation of the simulation system in billet caster of Steelworks Štore-Steel, Štore, Slovenia – one of the major European producers of spring steels, is elaborated.

 
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