Procast内部教程（Getting started系列）连铸.ppt

1、Getting started with ProCAST Continuous Casting of steel,Outline,This tutorial shows how to set-up a Continuous Casting model with the “Solid Transport” method. The approach is Eulerian, a fixed mesh is considered. The goal is to study the steady state behavior of a curved steel slab. (the only rele

2、vant result is the final steady state). Steady state Continuous casting Curved Steel slab : Section 0.3 * 1 m2 Main radius = 10m Casting speed = 2 cm/s Pre-Processing steps Thermal : Solid Transport imposed via user functions Thermal + Flow : Velocity BC and Solid transport imposed via user function

3、s Pressure BC Use of the thermal result as initial condition (extract),1,Steady State,Thermal Only Calculation,2,Steady State,Load the mesh in PreCAST,1,Use the explorer to go to the right location,3,Materials,Assign Materials as indicated,4,Interface,Interface,NB : A good recommendation is to set t

4、he Casting as the first material in the pair. The first material in the pair is the master and will always appear in red color. A right-click on the pair allows to invert order.,5,Assign Surface : Add BCs to the model,heat BC for the side surfaces of the mold heat BC for the casting faces heat BC fo

5、r the top bottom and bottom surfaces of mold one temperature BC for the top of the casting,Boundary Conditions,6,First Heat BC : cooling of external faces of the casting,NB: X, Y, Z keys allow rotating the model along respective axis. Rotation step is 10 Press CTRL simultaneously to reverse rotation

6、,Boundary Conditions,7,Boundary Conditions,Second heat BC : Lateral cooling of the Mold,8,Boundary Conditions,Third heat BC,1,1,Select and store the top and bottom faces of the mold,9,Boundary Conditions,Temperature BC,1,Select and store the top surface of the casting,1,10,Process Gravity,Set the gr

7、avity as usual, in the Process Gravity menu,11,Process Assign Volume,The solid transport velocities should assigned in the Process Assign volume Menu,Leave blank spaces for X and Y components (U and V values) Set 0 for Z component (W value) Click left on the “Function” boxes for U and V.,1,Add a new

8、 “Solid Transport” in the Process condition,12,Process Assign Volume,The Solid transport velocity should be tangential to the slab, in each point. Knowing the casting speed and the main Radius of the machine, the angular speed Omega is derived, as well as the angle, and finally, the two components o

9、f the velocity.,R=X2+Y2,Y,X,V = R*Omega,Vxx=Vsin ,Vyy=Vcos ,Center in (0,0),Omega =d/dt,casting speed,13,Process Assign Volume,Solid Transport Velocity : User Function vxsolidtransport .c,14,Process Assign Volume,Solid Transport Velocity : User Function prefix_vysolidtransport.c,1,Repeat the same pr

10、ocedure for the Y component of the transport velocity.,15,Initial Conditions,Set Initial Conditions as constant :,16,Run Parameters,In the General RP panel, select a stop criterion (here, final time) and a maximum number of steps.,17,Run Parameters,For a Thermal Only Calculation, set POROS 0 PIPEFS

11、0, FLOW 0 FREESF 0 Click Apply when you are done,18,Save files, Exit PreCAST Run DataCAST then ProCAST,Launch Calculation,19,Steady State,Results (thermal),Only the steady state result is relevant. Here, steady state is reached after 1200s.,20,Steady State,Results (thermal),You can use different cut

12、-off values for solid fraction, in order to see the shape of sump,21,Steady State,Thermal + Flow Calculation,22,Thermal + Flow : first steps,The first steps are similar to the Thermal only conditions Operations regarding Materials, Inteface, heat and Temperature BC are the same,Remember to set “Empt

13、y-NO” for casting material.,23,Boundary Conditions,Add a Velocity Boundary Condition,24,Solid Transport Velocity : User Function vximposed,1,The user functions for X and Y fluid velocity : prefix_vximposed.c and prefix_vyimposed.c should be copied from the “template” directory,Boundary Conditions,25

14、,Solid Transport Velocity : User Function vyimposed,1,Again, the programming of prefix_vyimposed.c function is very similar to what is done for solid transport,Boundary Conditions,For a thermal + Flow solve, you need a total of 4 user functions : 2 for solid transport velocity and 2 for fluid veloci

15、ty. Be aware that if you change the value(s) of the Radius, casting speed or coordinate of the center in one function, you have to do the same changes in the others in order to be consistent. Be aware also that you need a C compiler (plus SDK for 64 bit machines) to run ProCAST with user function. A

16、 free compiler is available, just follow the help online for download link and installation instructions.,26,Boundary Conditions,Pressure BC,Add a pressure Boundary Condition,1,The pressure BC is here to ensure mass conservation : the density of the out coming metal (solid) will vary during the solv

17、e and is larger than the incoming liquid. The pressure BC allows to compensate for that.,27,Initial Conditions,To save CPU time, a Thermal calculation should be performed first. Then you can use the “Extract” tool and use the thermal only results as the initial thermal field for the thermal + flow s

18、olve. :,28,Run Parameters,Thermal RP are the same Flow RP : FLOW 1 - FREESF 0 PREF=1bar (reference pressure = BC pressure) WSHEAR 0 WALLF 1 Click Apply when you are done,29,Save files, Exit PreCAST Run DataCAST then ProCAST,Launch Calculation,30,C Compiler,Launch Calculation,To run ProCAST with User Function, do not forget that you