Solidified Shell Thickness Estimation in Continuous Casting Mold
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Solution Overview
Problem
Existing methods for estimating solidified shell thickness in continuous casting molds fail to accurately predict local variations in thickness direction and width direction, leading to potential breakouts and productivity issues during high-speed casting.
Innovation Solution
A device and method that utilize a three-dimensional transient heat transfer calculation model to estimate solidified shell thickness, converting molten steel flow rate into semi-solidified region heat conductivity, allowing for accurate prediction of thickness distribution across both width and thickness directions of the mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed casting is performed to improve productivity, then casting speed increases, but solidified shell thickness at mold lower end decreases and distribution becomes ununiform
Solution Approach 1:
The invention transitions from one-dimensional heat transfer calculation (height direction only) to three-dimensional transient heat transfer calculation, enabling estimation of solidified shell thickness in width direction, thickness direction, and height direction simultaneously. This dimensional expansion allows accurate prediction of local thinning in all spatial directions while maintaining high-speed casting conditions.
Solution Approach 2:
The invention introduces molten steel flow rate as a dynamic parameter that converts to heat conductivity in the semi-solidified region. By incorporating this parameter change, the model accounts for transient variations in molten steel flow and their impact on heat transfer, enabling accurate solidified shell thickness estimation under varying high-speed casting conditions.
2Device complexity
If one-dimensional heat transfer calculation is used to simplify computation, then calculation complexity decreases, but ability to predict local thinning in width and thickness directions is lost
Solution Approach 1:
The invention implements three-dimensional transient heat transfer calculation that computes temperature distribution and solidified shell thickness in width direction, thickness direction, and height direction. This multi-dimensional approach captures local thinning phenomena in all directions while maintaining computational feasibility through efficient numerical methods.
Solution Approach 2:
The invention converts molten steel flow rate to heat conductivity parameter in the semi-solidified region, enabling the three-dimensional heat transfer calculation to account for transient flow variations. This parameter transformation allows the complex 3D calculation to incorporate dynamic flow effects without requiring direct coupled flow-heat transfer simulation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables high-accuracy estimation of solidified shell thickness in both width and thickness directions, preventing breakouts and improving productivity by accurately predicting potential thinning regions.
Implementation Method 1
a three-dimensional transient heat transfer calculation unit that solves a three-dimensional transient heat conduction equation
Implementation Method 2
solves a three-dimensional transient heat conduction equation to estimate a solidified shell thickness in the mold
Data Source
Figure 1
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AI summary
A device for estimating a solidified shell thickness in a mold according to the present invention includes an input device that receives an input of measurement results of a temperature and components of molten steel in a tundish of continuous casting facilities, measurement results of a width, a thickness, and a casting speed of a cast slab casted in the continuous casting facilities, and molten steel flow rate distribution in a mold, a model database that stores a model expression and a parameter related to solidification reaction of molten steel in the mold of the continuous casting facilities, a convertor that converts a molten steel flow rate in the mold input to the input device into a heat conductivity parameter, and a heat transfer model calculator that estimates a solidified shell thickness in the mold based on temperature distribution of the mold and steel in the mold calculated by solving a three-dimensional transient heat conduction equation using the measurement results of a temperature and components of molten steel in the tundish of the continuous casting facilities, the measurement results of a width, a thickness, and a casting speed of a cast slab casted in the continuous casting facilities, the model expression, the parameter, and the heat conductivity parameter calculated by the convertor.