3-dimensional Mathematical Model for the Analysis of Continuous Beam Blank Casting Using Body Fitted Coordinate System

A 3-dimensional mathematical model has been developed for a fully coupled analysis with fluid flow and heat transfer in the continuously cast beam blank. A body fitted coordinate system was introduced for the complex geometry of the beam blank. This enables the general program to be formulated to analyze the transport phenomena in the arbitrary shaped geometry. The effects of turbulence and natural convection on fluid flow in the strand were incorporated. The temperature distribution and solidification of the strand coupled with the fluid flow were also analyzed. The solidus and liquidus temperatures of the steel were determined with microsegregation model under the given composition of steel. The effects of fluid flow on the heat transfer, the solidification of steel and the development of shell thickness during the casting of the beam blank were simulated at various casting speed. The recirculating flows appeared in the regions of the web and the flange tip, however, it was not developed between the nozzle and the flange center. The flow normal to the casting direction in the region of the web moved to the upper region of the flange tip near the meniscus. The development of solidifying shell in the center of the flange tip was slowest at the initial stage of the solidification. The development of solidifying shell in the regions of the fillet and the flange center became slow down after the impinging of the inlet flow from the nozzle on the solidifying shell.