Numerical Simulation of Process of Electromagnetic Casting and Technology Features

This paper presents a proposed numerical model of casting process into electromagnetic crystallizer mold and results obtained when applying it to the analysis of the processes of casting aluminum ingots with a diameter of 25 to 30 mm. The numerical model is based on the calculation of the electromagnetic field by means of user-defined function (UDF) in Fluent software combined with the simulation of processes related to free surface using volume of fluid (VOF) method and crystallization on Kozeny-Carman method. The results of solving the search problem on the determination of a set of parameters ensuring the stable formation of an ingot of the required diameter as well as the results of simulation of emergency and special modes are shown. The article also presents application results of the modes identified on the laboratory installation of casting into electromagnetic crystallizer using ElmaCast® technology for the production of ingots from experimental alloys "Nikalin" and "Alcimac".