Domestic research projects

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Research projects (co)funded by the Slovenian Research Agency.

 

  • Member of University of Ljubljana: UL Faculty of Mechanical Engineering
  • Project code: L2-9246
  • Project title: Multiphysics and multiscale numerical modelling for competitive continuous casting
  • Period: 01.07.2018 - 30.06.2021
  • Range on year: 0,75
  • Head: prof. dr. Božidar Šarler
  • Research activity: Engineering sciences and technologies 
  • Research Organisation: Link
  • Researchers: Link
  • Citations for bibliographic records: Link
Abstract:

The co-founder of the project is Slovenian state-of-the-art manufacturer of steel Štore Steel. The company is a global player, renown for its topmost quality products, used in automotive, aircraft, space, sports and military industries. Its products are mainly exported to demanding foreign markets since they stand out in terms of technical superiority and exceed the high quality standards set by the costumers. The company possesses the ability to process special orders and to grant short delivery periods to its customers.

The project contents are tied to a sequence of our previous, successfully completed applied research projects: L2-5387 (2002-2005) Modelling and optimisation for competitive continuous casting, L2-9508 (2006-2009) Modelling of microstructure for continuous casting of steel with topmost quality, L2-3651 (2010-2014) Simulation and optimisation of casting, rolling and heat treatment processes for competitive production of topmost steels, L2-6775 (2014-2017) Simulation of industrial solidification processes under the influence of electromagnetic fields, the connected projects of the EU Framework Programmes, projects with USA and China. Based on the gained knowledge, we have equipped and automated the new, in 2016 installed, continuous casting of steel machine with advanced computational models.

The company is systematically investing research efforts towards defect-free continuous casting with the goal of topmost product quality. These efforts strongly depend on advanced numerical simulation of the process. The main aim of this project is to further develop and refine the existing continuous casting on-line and off-line models for prediction and mitigation of casting defects such as: macrosegregation, inclusions, shape distortion, porosity, hot tearing, decreased surface quality and both internal and surface cracks.

In the project, an integrated multiscale, multiphysics, and multiobjective model of the mentioned continuous casting processes, will be further established and will describe the phenomena from the top of the mould up to the cooling of the billets. A model of such complexity has never been developed before and will be world leading. It will integrate thermomechanics, thermofluids, thermodynamics, transport phenomena, electromagnetic science and technology, and magnetohydrodynamics. The multiscale coupling will include relations between the process parameters, product macrostructure, microstructure and properties. The multiphysics coupling will include relations between the solution of electromagnetic field and temperature, velocity, concentration, deformation and stress fields. The multi-objective features will enable proper setting and optimisation of process parameters as a function of casting productivity, product quality and/or environmental impact.

The macrostructure models will rely on continuum mechanics and coupled equations of mass, energy, momentum, turbulent energy and dissipation rate, and species transfer in the Eulerian system. The microscopic models will be based on the Lagrangian movement of the representative part of the microstructure. The microstructure models will be based on our original point automata and phase-field methods. The electromagnetic field is solved through Maxwell equations. The models will be evaluated in realistic three dimensional settings by using our original meshless methods for which we received numerous awards. The numerical implementation will be established on common computational platform that will be developed for the needs of this project. The platform will utilize domain-decomposition approach. This will exploit the parallel computing capabilities of modern supercomputers on which it will be installed. The models will be validated based on in-plant measurements, laboratory materials characterisation and water similarity models. The final goal of this modelling is the prediction of the product properties as a function of complex process parameters as well as estimation of the possible design changes of the casting devices.

The expected effects of the project are: improved quality, enhanced process capabilities and productivity in production of a broad spectrum of products. Like in the previous projects, the results will be implemented in production, published in top impact factor journals and presented as keynotes on large international meetings.

The phases of the project and their realization:

The project is organized into following interlinked workpackages:

  1. Refinement of the physical models
    1. Fluid mechanics part of solidification
    2. Solid mechanics part of solidification
    3. Microstructure modelling
  2. Parallel numerical implementation on supercomputer
  3. Multiphysics and multiscale coupling
  4. Verification and validation

Use of the models in industry