MAGMASOFT® 6.0 - MAGMA CC – More Simulation for Continuous Casting
MAGMA CC users benefit from new capabilities: They can consider the influence of electromagnetic stirring on the flow and thus better evaluate the quality of their product. In addition, the thermomechanical behavior between strand and mold is better defined by gap-dependent heat transfer coefficients. It is also possible for users to display moving geometries in the Result Perspective. This allows an accurate interpretation of the real starting process including the visualization of the moving starting block.
MAGMA CC - New EMS Simulation
We proudly announce our new simulation of EMS which will be available with with the next MAGMA CC version.
Product Quality, Process Robustness and Cost-Effective Productivity
The continuous casting process is of crucial importance for the manufacture of semi-finished products. Liquid metal is introduced into a short, intensively cooled mold, which may include graphite inserts, from a tundish or launder. At the same rate, metal is withdrawn from the mold, where the presence of a stable solidified shell at the end of the mold needs to be assured. In the start-up phase, a starting ingot is positioned in the mold, and after reaching the desired filling level, the starting ingot is removed and the metal inflow adjusted accordingly. The primary cooling in the mold is of decisive importance for the formation of a stable solidified shell. Further cooling of the strand takes place in the so-called secondary cooling zone. For process design and optimization, MAGMA CC, is a fully integrated and practically relevant turn-key solution providing meaningful information for the simulation based optimization of vertical and horizontal continuous casting processes.
Visualization of the complete aluminum continuous casting process
Metal inflow and nozzle design
Velocity distribution during the inflow of the melt
Determination of the liquid pool including the mushy zone
Particle flow in a tundish showing turbulences and inclusions
Displacement result showing the gap formation in the mold
Consideration of spray water cooling
Visualization of a bow type casting machine
MAGMA CC supports continuous casters to reach the following objectives:
- Layout and optimization of launders and tundishes to improve flow conditions
- Layout and optimization of immersion nozzles for minimizing inclusions
- Design and optimization of the mold (e.g. conicity, cooling performance, materials)
- Optimization of the process (e.g. optimal casting speed, adapted secondary cooling)
- Determination of temperature distributions during start-up and quasi-stationary operation for various process conditions to ensure the required quality
- Optimization of quality-relevant flow phenomena both during start-up and quasi-stationary operation, caused by the inflowing metal and by natural convection
- Calculation of the stress distribution in the strand and mold as well as stress-relevant quality criteria
MAGMA CC can be used for the casting of copper and copper alloys, aluminum alloys and steel. The program can be used to improve product quality before start of production as well as for continuous improvement during production. With the help of virtual Design of Experiments and autonomous optimization, the process and product-specific limits of the relevant process variables are determined for a safe production of high quality products. MAGMA CC includes the calculation of flow, solidification and stresses, taking into account primary and secondary cooling. Thus, the interactions between the inflowing melt, the solidified shell of the strand and the mold can be judged.
CC Temperature
Thermal convection during solidification influences the quality
Modeling of flow, velocities and inclusions in the tundish
Velocity distribution by using a typical nozzle design for thin slab casting
Solidified shell and sump profile during DC casting of aluminium
Crack prediction with dedicated stress results based on temperature distribution
Displacement result to show gap formation in the primary mold
Publication in Area of Continuous Casting
Autonomous Mathematical Optimization of Continuous Casting Processes
Editors:
Wilfried Schäfer, Götz Hartmann, Erik Hepp, MAGMA GmbH, Aachen, Germany
Dieter G. Senk, Sonja Stratemeier, IEHK RWTH Aachen University, Germany
The publication introduces a numerical simulation based optimization strategy, following rigorous thermodynamic and thermo mechanical models as well as a strictly methodic approach.
