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UBC Theses and Dissertations
A coupled thermal - fluid flow model of the horizontal direct chill casting process for T-ingot Lane, Malcolm D.
Abstract
In recent years, Horizontal Direct Chill (HDC) casting has gained popularity as a method for processing primary aluminum. In an attempt to further develop the knowledge and understanding necessary to enhance HDC casting capabilities in industry and improve its economic viability, a coupled thermal-fluid flow model of T-ingot casting has been developed. The model, developed using the commercial computational fluid dynamics software, ANSYS CFX-10.0, predicts the temperature and flow fields which occur during aluminum T-ingot HDC casting under steady-state operational conditions. Buoyancy, turbulence, solidification effects including flow damping and latent heat release, and boundary conditions were accounted for using methods that represent the physics occurring in the industrial process. Predictions for HDC T-ingot casting of pure and foundry (alloy A356) aluminum were compared to measurements made on industrially cast ingots. The measurements conducted included: drained sump profiles (6 in total), secondary dendrite arm spacings (SDAS), and location of macrostructure features. In all cases, the predictions matched the measurements well, providing confidence in the model and the methodology used. Throughout development of the model, sensitivity to modelling methodology as well as process and numerical parameters were explored. To simplify comparison, an extensive analysis was conducted by varying single features of a baseline model to show the importance of the modelling methodologies and process parameters.
Item Metadata
Title |
A coupled thermal - fluid flow model of the horizontal direct chill casting process for T-ingot
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Creator | |
Publisher |
University of British Columbia
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Date Issued |
2007
|
Description |
In recent years, Horizontal Direct Chill (HDC) casting has gained
popularity as a method for processing primary aluminum. In an attempt to further
develop the knowledge and understanding necessary to enhance HDC casting
capabilities in industry and improve its economic viability, a coupled thermal-fluid
flow model of T-ingot casting has been developed. The model, developed using
the commercial computational fluid dynamics software, ANSYS CFX-10.0,
predicts the temperature and flow fields which occur during aluminum T-ingot
HDC casting under steady-state operational conditions. Buoyancy, turbulence,
solidification effects including flow damping and latent heat release, and boundary
conditions were accounted for using methods that represent the physics occurring
in the industrial process.
Predictions for HDC T-ingot casting of pure and foundry (alloy A356)
aluminum were compared to measurements made on industrially cast ingots. The
measurements conducted included: drained sump profiles (6 in total), secondary
dendrite arm spacings (SDAS), and location of macrostructure features. In all
cases, the predictions matched the measurements well, providing confidence in the
model and the methodology used.
Throughout development of the model, sensitivity to modelling
methodology as well as process and numerical parameters were explored. To
simplify comparison, an extensive analysis was conducted by varying single
features of a baseline model to show the importance of the modelling
methodologies and process parameters.
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Genre | |
Type | |
Language |
eng
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Date Available |
2011-02-22
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Provider |
Vancouver : University of British Columbia Library
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Rights |
For non-commercial purposes only, such as research, private study and education. Additional conditions apply, see Terms of Use https://open.library.ubc.ca/terms_of_use.
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DOI |
10.14288/1.0078594
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URI | |
Degree | |
Program | |
Affiliation | |
Degree Grantor |
University of British Columbia
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Campus | |
Scholarly Level |
Graduate
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Aggregated Source Repository |
DSpace
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Item Media
Item Citations and Data
Rights
For non-commercial purposes only, such as research, private study and education. Additional conditions apply, see Terms of Use https://open.library.ubc.ca/terms_of_use.