Particularly for trumpet designs, the teeming process is essential for the manufacturing of steel ingots and influences the quality of products. Since it controls ingot quality, starting mold filling is absolutely essential. Flow patterns in this vital phase are investigated using a three-dimensional model of a two-mold gating system. Underlining the requirement of careful refractory material selection to retain process integrity and ingot quality, the study also indicates significant wall shear stress at the center stone, horizontal runner, and vertical runner elbow. By the way, this study is conducted, relying on the reference paper titled “ Mathematical Modeling of Initial Filling Moment of Uphill Teeming Process Considering a Trumpet”.

Figure 1: Different parts of the uphill teeming system, taken from the reference paper

Simulation Process

The base model given in the reference paper has several parts, including trumpet, mold, and runner. As a preliminary work, it was divided into separate parts in ANSYS Design Modeler to generate a structured grid further. 84198 quadrilateral cells fill the domain produced by ANSYS Meshing. It goes without saying that the molding process has to be scrutinized over time, so this simulation follows transient (unsteady) formulation. The interaction between two phases (air & molten steel) plays a prominent role in the molding process (teeming). This is solved using the volume of fluid (VOF) multiphase model.

Post-processing

The liquid volume fraction is shown on the contour plot; red denotes totally liquid areas and blue represents air or empty parts. The simulation records the intricate mold flow patterns. Particularly fascinating is the turbulent behavior shown in the horizontal runner and at the bottom of the vertical runner, shown by the color mix reflecting different liquid fractions. This turbulence is essential since it can affect the production of flaws in the produced ingot. The mold itself displays a non-uniform filling pattern with a more turbulent middle section and a larger liquid proportion close to the walls. This points to possible sources of worry for trapping of mold flux or inclusion development. Surface instabilities that can compromise the surface quality of the ingot are shown in the wavy pattern of the interface between molten steel and air in the mold.