An improved combination of ruler and local electromagnetic brakes for continuous casting process

• Published in: Journal of manufacturing processes 2023-01, Vol.85, p.1037-1053
• Main Authors: Hosseini, Seyed Mohammad, Amani, Ehsan
• Format: Article
• Language: English
• Subjects: Computational fluid dynamics; Continuous casting; Electromagnetic brake; Solidification
• ISSN: 1526-6125; 2212-4616
• DOI: 10.1016/j.jmapro.2022.12.030

In the present study, using computational fluid dynamics, we aim to systematically propose an improved combination of local and ruler ElectroMagnetic Brakes (EMBr) to reduce the surface and internal defects in the thin-slab steel continuous casting. To achieve this goal, first, each of governing submodels, including turbulent fluid flow and heat transfer, solidification, and electromagnetics, is carefully validated. Then, the model is used to evaluate the performance of different EMBr design configurations in terms of six flow metrics, i.e., the flow pattern, solidified shell thickness, surface velocity, turbulent kinetic energy, level fluctuation, and superheat transport. The results manifest that the braking effect, imposed by the combinations of ruler and local EMBrs, effectively resolves the problem of uneven solidified shell growth, especially for SEN-type casters. On the other hand, using local EMBrs on the thin wall midway the SEN and meniscus can result in unstable flow structures which are prone to change to the detrimental single-roll pattern under the perturbations in the operating conditions. Finally, the best performance is achieved by the combination of a single-ruler EMBr below the SEN and a couple of local EMBrs near the center of the meniscus. This configuration substantially increases the superheat transport to the surface and decreases surface mean and fluctuating velocities, especially at the meniscus near the walls, and can effectually prevent the formation of defects. [Display omitted] •ElectroMagnetic Brakes (EMBrs) effect on continuous casting process is investigated.•An improved combined EMBr configuration is proposed using six flow metric criteria.•The new design effectively resolves the problem of uneven solidified shell growth.•The local EMBrs imposed near the center of the meniscus were most effectual.•The ruler EMBr employed under the SEN enhances superheat transport to the meniscus.