Numerical Analysis to Investigate the Effect of Solidification Parameters on the Pull-In Effect of Continuous Casting

Direct chill (DC) casting is a method of solidifying molten metal into a semi-finished billet, bloom, or slab prior to rolling in finishing mills using an external continuous chilling technology. However, its operational improvement remains a focus of researches due to the ingot curve formed at bottom and side. The purpose of this research is to examine the thermal and mechanical properties created during the direct chill casting process in order to determine the base and side curvature using a CFD technique. The effect of vertical pull-in direct chill casting of aluminum ingots was investigated using a numerical model based on multiple physics. Thermal and mechanical simulations are performed using ANSYS mechanical software. The development of the ingot during the transient solidification process is aided by the use of a dynamic mesh method. The element kills, and generated concepts are utilized to determine the ingot's deformation. The results demonstrate that the developed model may be utilized to forecast deformations in ingots caused due to thermo-mechanical characteristics throughout the direct chill casting process. The deflection of the slab increases as the molten metal temperature and casting speed decrease. The maximum deflection was determined to be 23.34 mm for the case at a molten temperature of 715 ℃ and a casting speed of 75 mm/min.