Simulation of horizontal centrifugal casting: Mold filling and solidification

Abstract

In order to simulate the mold filling and solidification of the outer shell of large work rolls being cast by horizontal centrifugal casting, the shallow water equations were adopted to solve the 2D average flow dynamics of the melt spreading inside the cylindrical mold. The model accounts for centrifugal force, Coriolis force, shear force, gravity and convective and diffusive energy transport. The solidification front was tracked by fulfilling the Stefan condition. Radiative and convective heat losses were included from both, the free surface and the outer wall of the mold. By introducing a stochastic factor to account for the irregular filling jet behavior an uneven spreading of liquid from the center of the mold towards the extremities was predicted. Thus, the formation of the first solid layer also happens unevenly. However, when the mold is covered everywhere with a solid layer, the solidification rate decreases and further filling increases the height of the liquid layer. With increase liquid height the amplitude of the free surface waves also increases. © 2014 ISIJ.