滑动水口控流下结晶器偏流与凝固的电磁搅拌调控
Control of biased flow and solidification in slide-gate mold via electromagnetic stirring
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摘要: 滑动水口控流因滑板不完全开启易诱发结晶器内偏流及凝固坯壳生长不均, 严重影响铸坯质量。电磁搅拌是调控结晶器流场的有效手段, 但在滑动水口控流条件下, 如何量化评估其对非对称流场及凝固行为的改善效果尚需深入研究。本文旨在揭示结晶器偏流机理, 并探究电磁搅拌对非对称流场及凝固行为的调控规律。针对某钢厂板坯结晶器, 建立包含电磁、流动及传热耦合的三维大涡模拟模型。引入"对称性指数"作为量化指标, 系统研究了搅拌电流和滑板开口度对流场结构及坯壳均匀性的影响。研究表明, 浸入式水口内部流场不对称是造成结晶器偏流的根本原因。无电磁搅拌时, 射流向内弧侧偏转, 导致内弧侧坯壳重熔严重; 施加电磁搅拌后, 形成的水平环流有效削弱了水口两侧速度差异, 显著改善流场对称性。增大搅拌电流, 平均对称性指数由0.62增加至0.71, 内弧侧坯壳重熔减轻; 但电流过大会加剧窄面坯壳冲刷。坯壳厚度标准差随电流增加呈先减小后增大趋势, 在电流为600 A时达到最小值(0.215 mm), 坯壳生长最均匀。此外, 滑板开口度的增加有助于提升流场对称性, 当线性开口度从50%增加至100%时, 平均对称性指数从0.64增加至0.75, 坯壳均匀性标准差降低至0.202 mm。电磁搅拌能有效抑制由滑动水口控流引起的非对称流动, 但需合理匹配搅拌强度以平衡流场对称性与坯壳冲刷之间的关系。综合考虑流场对称性与坯壳质量, 在滑板开口度为60%工况下, 最优搅拌电流为600 A。该研究结果可为板坯连铸工业现场优化电磁搅拌工艺参数、提升铸坯质量提供理论指导。Abstract: The incomplete opening of the slide plate is prone to inducing biased flow in the mold and non-uniform growth of the solidified shell, which critically affects slab quality. Electromagnetic stirring (EMS) is an effective method for regulating the mold flow field, yet further research is needed to quantitatively evaluate its improvement effect on asymmetric flow and solidification behavior under slide-gate control conditions. This study aims to reveal the mechanism of biased flow and investigate the regulation laws of EMS on the asymmetric flow field and solidification behavior. Focusing on a slab mold in a steel plant, a three-dimensional large eddy simulation (LES) model coupling electromagnetic, flow, and thermal fields was established. A "symmetry index" was introduced as a quantitative indicator to systematically investigate the effects of stirring current and slide gate opening rate on the flow field structure and shell uniformity. The results indicate that the asymmetry of the flow field inside the submerged entry nozzle (SEN) is the root cause of the biased flow in the mold. Without EMS, the jet deflects toward the inner radius (IR) side, leading to severe remelting of the IR shell. The application of EMS generates a horizontal recirculating flow that effectively reduces the velocity difference between the two sides of the nozzle, significantly improving flow field symmetry. As the stirring current increases, the average symmetry index rises from 0.62 to 0.71, and the remelting of the IR shell is alleviated; however, excessive current intensifies the scouring of the narrow face shell. The standard deviation of shell thickness decreases first and then increases with rising current, reaching a minimum of 0.215 mm at 600 A where shell growth is most uniform. Furthermore, increasing the slide gate opening rate helps enhance flow field symmetry; as the linear opening rate increases from 50% to 100%, the average symmetry index rises from 0.64 to 0.75, and the standard deviation of shell uniformity decreases to 0.202 mm. In conclusion, EMS can effectively mitigate asymmetric flow caused by slide-gate control, but the stirring intensity must be optimized to balance flow symmetry and shell scouring. Considering both flow field symmetry and shell quality, the optimal stirring current is determined to be 600 A under a 60% slide gate opening condition. These findings provide theoretical guidance for optimizing EMS process parameters and improving slab quality in industrial slab continuous casting applications.
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