Deeper understanding of process
Virtual variation of operation parameters
Assists in
–Identifying critical process parameters
–Optimizing production process
–Improve productivity
2. ELKEME
• The R&D Center of VIOHALCO
• Founded 1999
• Industrial research, technological
development and analysis of
–Aluminum
–Copper
–Steel
–Zinc
Lab/Section Name 2
3. ELKEME
• Applied technology research towards
– Quality Improvement of existing products
– Development of new, innovative, high added
value products
– Optimization of Industrial Processes
• Energy and cost efficiency
• Health and safety
• Environment and sustainable growth
Numerical Modeling Department 3
4. ELKEME
• State of the art laboratories
• Highly capable scientists, engineers,
technicians
• Continuous professional development
• Collaborations with External Laboratories
• Research projects in Metallurgy, Material
Sciences and Environmental Engineering
• Build knowledge and competence network
Numerical Modeling Department 4
5. ELKEME
• Long term relationships with academic and research
institutes (National Tech. Univ. of Athens, Universities of
Patras, Ioannina, Delft, Ghent, Manchester)
• Supervision of Diploma/Master’s/PhD theses
• Student training programs
• Seminars
• International collaborations
• Participation in international scientific/engineering
associations
• Contributions to scientific journals and conferences
(ICEFA, ICAA, ICEAF, Thermec, TMS, etc.)
Numerical Modeling Department 5
14. Numerical Modeling
• Deeper understanding of process
• Virtual variation of operation parameters
• Assists in
– Identifying critical process parameters
– Optimizing production process
– Improve productivity
Numerical Modeling Department 19
15. Numerical setup
• ANSYS Fluent 12.0/16.2, solidification model
• Double precision, axisymmetric, 1mm mesh resolution
• Geometry: mold, distributor, air gap, water curtain
• Insulated top (graphite flux)
• DHP Copper physical properties (thermal properties,
solidification properties: latent heat, liquid fraction,
porosity)
– No thermal shrinking
– No micro/macro solute segregation
• Casting speeds: A→1.15A→1.20A→…
• Various cooling setups
Numerical Modeling Department 20
16. Numerical problems
• The simulation of casting is a very difficult
numerical problem. The fast transition from the
liquidus to the solidus temperature (energy
release-latent heat, viscosity transition from liquid
to solid) makes the equations very “stiff”: small
changes lead to instabilities and to the destruction
of the solidification front
• It is very difficult to find a convergent solution
• Unless one finds a convergent solution, one must
not trust the small details of the final result
Numerical Modeling Department 21
17. Numerical problems
• We tried many different numerical
approaches
• We were able to obtain convergent
solutions that we can trust!
Numerical Modeling Department 22
27. Primary Conclusions
• The original setup had limitations that did
not allow the increase of productivity
• Setup asymmetries
Fix
Numerical Modeling Department 32
28. Revisited problem 2015
• Basic factors related with productivity:
– Depth/Geometry of molten metal in mould
Modifications
Speed increase 15-20% !
Need to go even faster!
• Setup asymmetries
Fixed !
Numerical Modeling Department 33
29. Preliminary results 2015
• The shape of the solidification front
consists of 3 parts:
1. The growing solidification front in the mold
2. An almost cylindrical front in the air gap
region below the mold
3. A V-shaped final solidification front in the
water curtain region
Numerical Modeling Department 34
38. Conclusions
• The shape of the central solidification front
depends only on the casting speed
• The improvement IS NOT due to changes in
the shape of the front at the center
• Increased metalostatic pressure compensates
for solidification shrinkage porosity
• Thermo-mechanical investigation of cooling
beyond solidification
Numerical Modeling Department 44
39. Conclusions
• Increasing the height of the air gap leads
to secondary problems due to very slow
solidification rates and/or remelting at
intermediate radii
• Future trials:
– Modified cooling
– Thermo-mechanical investigation with ANSYS
Mechanical
Numerical Modeling Department 45