A numerical simulation of the DC continuous casting using average heat capacity

Continuous casting is one of the prominent methods of production of metals. The effective design and operation of continuous casting machines needs complete analysis of the continuous casting process. In this paper, a finite volume model has been developed and applied to compute the fluid flow, temperature and flux distributions within the liquid, mushy and solid zones in the mold and cooling regions of an aluminum alloy direct-chill continuous casting machine. The average heat capacity method was successfully implemented for the analysis of conjugate heat transfer during the phase change phenomenon. The effect of phase change on convection is accounted for using a new modification in the velocity vector. The effect of casting speed on fluid flow, temperature and surface heat flux evolution was investigated. The predicted temperature distribution and surface heat flux were compared with experimental measurements and numerical solutions given in the literature. A reasonable agreement was obtained.