Non Ferrous Publications

Erik Hepp, Sebastian Koldorf

The classical use of simulation solutions evolves to process optimization. Integrated statistical tools such as virtual Design of Experiments allow to perform systematic virtual experimentation of a process window. This enables the expert to identify significant process parameters and to investigate the effect of parameter changes without expensive trials in the shop floor. Based on this knowledge, it is possible to optimize casting processes that are both, cost effective and robust with respect to process variations.

State of art simulation tools provide quantitative insights in flow, solidification and stress formation for continuous casting processes. This includes the entire process, from the tundish and the flow into the mold to the solidifying strand that is withdrawn through various cooling zones. Process simulation provides important information about quality and productivity to evaluate process alternatives. This paper will discuss the modelling of electromagnetic stirring (EMS) and its impact on the flow behaviour. Another focus will be the evaluation of new criteria to avoid the formation of cracks. With the help of a stress calculation results for cold crack formation and hot tearing are available. Stress simulation is also been used to described the gap formation in mold and the corresponding change of heat transfer conditions.

The results are shown at industrial examples for billets and bloom casters. With the availability of the integrated process knowledge of a digital twin, it is possible to identify optimal operating points for quality improvements and productivity increases. The objective is to derive a comprehensive model for online monitoring and optimized dynamic online control of the cooling and solidification process.

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