NUMERICAL SIMULATION OF THE FORMATION AND THE DRIPPING OF DROPLET IN THE ELECTROSLAG REMELTING PROCESS

Abstract: Based on the magnetohydrodynamic(MHD) module of the commercial computational fluid dynamics software FLUENT, a three-dimensional mathematical model was developed to describe the multi-field coupling phenomenon in the Electroslag Remelting process. The model predicted value is in good agreement with the experimental measurements. The simulation results show that, during the melt dripping process, the resistance of the Electroslag Remelting system is decreasing while the current density and velocity, as well as the temperature are increasing gradually. The maximum value of current density, electromagnetic force and velocity appears when the melt droplet detaches and the quality of large droplets fall into the slag-metal interface. The maximum value of the current density is increased by almost one order of magnitude. And the maximum value of the electromagnetic force and velocity increased by 2.5 and 4.7 times, respectively. The maximum value of joule heating and temperature appears when the droplets fall into the slag-metal interface. The maximum value of the joule heating and temperature increased for about 174.7 % and 26.8 % when compared with the moment of the melt droplet formation. Key words: electroslag remelting；magneto-hydrodynamics；multi-field coupling；formation and dripping of the melt drople