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Software Package Predicting the Structure Formation of a Continuous Casting
The package's function is to predict the structure formation of continuous castings with the object of determining optimal operating practices.
The software allows to model thermal processes of continuous castings formation and to calculate the parameters of solidification kinetics (width and depth of the molten metal zone, width of the two-phase zone, thickness of the rim) at different points of time.
The software package works for different types of continuous casters (vertical, radial, curved casters), different types of steel and different casting cooling modes.
The package is equipped with a convenient graphic interface; the obtained data are represented in diagrams, graphs and tables (see Fig. 1). |
Figure 1 |
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Adequacy study.
To check the adequacy of the suggested model, the calculated data (for the temperature pattern) were compared with the results of experimental temperature measurements at the points of reference on the surface of a 125-mm casting. The results of the experiments (see table 1) confirm the model adequacy. |
| Point of reference |
T, °C (calculated) |
T, °C (experimental) |
| Exit from zone #1 (1,17 m away from the meniscus) |
1008 |
1050 |
| Exit from the secondary cooling zone (7,27 m away from the meniscus) |
1098 |
1065 |
| Entrance into the cutting zone ((the end of the processing line, 22 m away from the meniscus)) |
1043 |
~1000 |
Table 1
Calculated and experimental data comparison. | |
An example of the software package application to determine the optimal casting cooling mode.
| Basic Parameters |
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Mould |
| Operating length of the caster, m |
22 |
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Total mould length, m |
1 |
| Bending radius, m |
8 |
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Operating length of the mould, m |
0,77 |
| Casting geometry |
Bar |
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Thickness of the working wall, mm |
12 |
| Thermophysical properties |
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Water channel width, mm |
15 |
| Carbon content, % |
0,36 |
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Outer wall thickness, mm |
20 |
| Liquidus temperature, °C |
1508 |
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| Solidus temperature, °C |
1427 |
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Secondary cooling |
| Initial melt temperature, °C |
1516 |
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Cooling water temperature, °C |
15 |
| Casting elongation rate, m/min |
2,8 |
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During the experiments the secondary cooling parameters varied (length of the zones and cooling water discharge rate). | |
MODE 0 (standard) | |
Parameters of the secondary cooling zone
| Zone № |
Length, m |
Water discharge, l/min |
| 1 |
0,4 |
135 |
| 2 |
1,8 |
210 |
| 3 |
4,3 |
144 | 
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MODE 1 (optimal) | |
Parameters of the secondary cooling zone
| Zone № |
Length, m |
Water discharge, l/min |
| 1 |
0,4 |
135 |
| 2 |
2,3 |
150 |
| 3 |
6,5 |
170 | 
The package can be used to carry out multichoice studies for continuous casters development and to work out optimal operating practices (cooling modes, casting parameters, processing line configuration).
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