Computational modelling of thermal transport phenomena in continuous casting process based on non-orthogonal control volume approach

An efficient computational simulation scheme based on non-orthogonal control volume discretization and co-ordinate transformation techniques has been developed for solving the thermal transport phenomena, which involves tracking of the interface between solid and liquid phases (solidification front) and evaluation of the temperature profile during continuous casting operation. Conservation equations are reformulated in differential-integral form in terms of the transformed co-ordinates. All the terms arising from the non-orthogonality of the control volume have been retained in the numerical solution methodology, and a front tracking procedure has been formulated based on an iterative solution scheme. The formulation has been applied to solve the thermal transport phenomena in solidification processing of an Al-Mg alloy cylindrical ingot during continuous casting, which also includes axial conduction of heat. Theoretical evaluation of the solidification front and temperature distribution in the ingot are in good agreement with the experimentally measured data.