Modeling of Initial Mold Filling in Uphill Teeming Process Considering a Trumpet

Abstract: The flow pattern in the uphill teeming process has been found to be closely related to the quality of ingots and further to affect the yield of ingot production, which is crucial for the steel making process. The formation of non-metallic inclusion and entrapment of mold flux has been considered to be affected by the flow pattern in the gating system and molds by many previous researchers. The aim of this study is to investigate the flow pattern of steel in the gating system and molds during the initial filling stage. In addition, to study the utilization of swirl blade implemented at the bottom of the vertical runner on the improvement of initial filling condition in the mold. A three dimensional model of two molds gating system for 6.2 ton ingots from Scana Steel was adopted in the present work. A reduced geometry model including one mold and a runner, based on the method from previous researchers, was also used for comparison with the current more extensive model. Moreover, a reduced geometry model including one swirl blade and a runner was simulated to find effects of an increased-length vertical runner on the flow pattern improvement at the vertical runner outlet. Flow pattern, hump height and wall shear stress were respectively studied.A reduced geometry with homogenous inlet conditions fails to describe the fluctuating conditions present as the steel enters the mold. However, the trends are very similar when comparing the (hump height-surface height) evolution over time. The implementation of swirl blades gives a chaotic initial filling condition with a considerable amount of droplets being created when steel enters the molds during the first couple of seconds. However, a more calm filling condition with less fluctuation is achieved at the molds after a short while. Moreover, the orientation of the swirl blades affects he flow pattern of the steel. A proper placement of a swirl blade improves the initial filling conditions. The utilization of swirl blades might initially result in larger hump height. However, it gives fewer fluctuations as the casting proceeds. In the model without swirl blades, the maximum wall shear stress fluctuates with a descending trend as the filling proceeds. An implementation of swirl blades can decrease and stabilize the wall shear stress in the gating system. A special attention should be made in choosing refractory at the center stone, the horizontal runner near center stone and the vertical runner at the elbow. This is where the wall shear stress values are highest or where the exposure times are long.