Abstract
Modelling of continuous casting process and various approximations and idealisations applied therein have been reviewed and analysed computationally. To this end, a conjugate, turbulent fluid flow-heat transfer model, embodied in ANSYS Fluent™ V18.0, has been formulated, via the “enthalpy-porosity method” and validated subsequently, against previously reported experimental data from an industrial scale billet caster. Numerical predictions have indicated that while computational mold length, extent of SEN submergence, and near wall treatments (i.e., wall functions) of model equations do not have significant bearing on results, the mushy zone constant as well as turbulence model, on the other hand exert considerable influence on flow, thermal and solidification profiles within the descending strand. Furthermore, isothermal water modelling was shown to capture the details of molten steel flow in mold region reasonably accurately. Numerical analysis supported by experimental measurements confirm that heat transfer and solidification phenomena play key roles and the simplistic effective thermal conductivity-based models are generally inadequate to model complex thermo-fluid phenomena in continuous casting.
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12666-022-02819-8/MediaObjects/12666_2022_2819_Fig1_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12666-022-02819-8/MediaObjects/12666_2022_2819_Fig2_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12666-022-02819-8/MediaObjects/12666_2022_2819_Fig3_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12666-022-02819-8/MediaObjects/12666_2022_2819_Fig4_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12666-022-02819-8/MediaObjects/12666_2022_2819_Fig5_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12666-022-02819-8/MediaObjects/12666_2022_2819_Fig6_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12666-022-02819-8/MediaObjects/12666_2022_2819_Fig7_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12666-022-02819-8/MediaObjects/12666_2022_2819_Fig8_HTML.png)
Similar content being viewed by others
References
J. Savage and W. H. Pritchard: J. Iron Steel Inst.: 200 (1962) 41.
Mizikar E A, Trans. Metal. Soc. AIME 239 (1967) 1747.
Lait J, Brimacombe J K, and Weinberg F, Ironmaking Steelmaking 2 (1974) 90.
Mazumdar D, ISIJ Int. 29 (1989) 524.
Asai S, and Szekely J, Ironmaking Steelmaking 2 (1975) 205.
Huang X, Thomas B G, and Najjar F M, Metall. Trans. B 23 (1992) 339.
Aboutalebi M R, Hasan M, and Guthrie R I L, Metall. Mater. Trans. B 26 (1995) 731.
Shamsi M R R I, and Ajmani S K, Steel Res. Int. 81 (2010) 132.
Yin Y, and Zhang J, ISIJ Int. 61 (2021) 853.
Trindade L B, Nadalon J E A, Contini A C, and Barroso R C, Steel Res. Int. 88 (2017) 1600319.
Gupta D, and Lahiri A K, Metall. Mater. Trans. B 27 (1996) 695.
S. Yokoya, S. Takagi, H. Souma, M. Iguchi, Y. Asako and S. Hara: ISIJ Int., 38 (1 998) 1086.
Schurmann D, Willers B, Hackl G, Tang Y, and Eckert S, Metall. Mater. Trans. B 50 (2019) 716.
Ni P, Ersson M, Jonsson L T I, Zhang T A, and Jönsson P G, Metals 8 (2018) 910.
M. M. Aboutalebi, F. Lapointe, J. D’Amours, M. M. ISAC, and R. I. L. Gouthrie: JOM, 70 (2018) 2088.
R. Chaudhary, B. T. Rietow and B. G. Thomas, In Proceedings of the Materials Science and Technology (2009): International Symposium on Inclusions and Clean Steel, Pittsburg.
Launder B E, and Spalding D B, Comput. Meth. Appl. Mech. Eng. 3 (1974) 269.
V. R. Voller and C. Prakash: Int. J. Heat Mass Transf.: 30 (1987) 1709.
ANSYS FLUENT 12.0 User's Guide, Chapter-25 Solidification and Modelling.
Shih T H, Liou W W, Shabbir A, Yang Z, and Zhu J, Computers Fluids 24 (1995) 227.
Menter F R, AIAA JOURNAL 32 (1994) 1598.
Hong K-H, Kim C-S, Cha P-R, and Yoon J-K, Met. Mater. Int. 8 (2002) 111.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Avatar, K., Mazumdar, D. An Assessment of Physical and Mathematical Modelling approaches in the study of Flow and Solidification Phenomena in Continuous Casting of Steel. Trans Indian Inst Met 76, 1075–1084 (2023). https://doi.org/10.1007/s12666-022-02819-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12666-022-02819-8