Mathematical Modeling of ESR Process for Hollow Ingot with Current Supplying Mould

• Published in: Journal of iron and steel research, international Vol. 22; no. 3; pp. 192 - 199
• Main Authors: CHEN, Xu, LIU, Fu-bin, JIANG, Zhou-hua, LI, Hua-bing, ZANG, Xi-min, DENG, Xin
• Format: Journal Article
• Language: English
• Published: Singapore Elsevier Ltd 01.03.2015; Springer Singapore
• Subjects: ANSYS软件; Applied and Technical Physics; electroslag remelting; Engineering; finite element method; hollow ingot; Machines; magnetically driven fluid flow; Manufacturing; Materials Engineering; Materials Science; Metallic Materials; Physical Chemistry; Processes; T-shaped current supplying mould; temperature field; 供应; 数学建模; 模具; 电流; 电渣重熔; 空心钢锭; 自动控制系统; finite element method; hollow ingot; magnetically driven fluid flow; T-shaped current supplying mould; electroslag remelting; temperature field
• ISSN: 1006-706X; 2210-3988
• DOI: 10.1016/S1006-706X(15)60029-2

With ificreasing demand for large cylindrical forgings, a new technology--electroslag remelting （ESR） for direct manufacture of hollow ingots rather than solid ingots has been developed. The main features of the process include a T-shaped current supplying mould （CSM）, double power supply, an ingot withdrawing system, a metal level automatic control system based on a level sensor using the electromagnetic eddy current method, and the exchange of a consumable multi-electrode. ANSYS software was used to calculate the fluid flow and heat transfer in the slag bath 1 and metal pool of this ESR hollow ingot process with its T-shaped CSM. The mathematmal model was Verified by measuring the geometry of the liquid metal pool as observed in the macrostructure of 4650 mm （external diameter）/ 4450 mm （internal diameter） hollow ingots by sulphur print method： the. observed shape and depth of the s!ag bath were consistent with the simulated results. Simulation of the ESR process can improve understanding of the process and allow better operating parameters to be selected.