Mathematical modeling of coupled turbulent flow and solidification in a single belt caster with electromagnetic brake

A mathematical model has been developed to simulate turbulent fluid flow and solidification in the presence of a DC magnetic field in an extended nozzle for metal delivery to a single belt caster. This paper reports on predicted effects of DC magnetic field conditions in modifying flows and solidification behavior in the metal delivery system. It is shown that the application of a DC magnetic brake to the proposed system can result in a reasonably uniform feeding of melt onto the cooled moving belt. This, in turn, optimises the rate of even shell growth along the chilled substrate. In order to account for the effects of turbulence, a revised low-Reynolds k–ε turbulent model was employed. A Darcy-porosity approach was used to simulate fluid flow within the mushy solidification region. Simulations were carried out for plain carbon steel strip casting. The fully coupled transport equations were numerically solved using the finite volume method. The computed flow patterns were compared with those reported in the literature. The performance of the magnetic flow control device proposed in this work is evaluated and compared with flow modifications obtained by inserting a ceramic filter within the reservoir.     

Discretisation procedures for multi-physics phenomena

Procedures are described for solving the equations governing a multi-physics process. Finite volume techniques are used to discretise, using the same unstructured mesh, the equations of fluid flow, heat transfer with solidification, and solid deformation. These discretised equations ofe then solved in an integrated manner. The computational mechanics environment, PHYSICA, which facilitates the building of multi-physics models, is described. Comparisons between model predictions and experimental data are presented for the casting of metal components.     

Simulation of direct chill casting under the influence of a low-frequency electromagnetic field

A comprehensive, multiphysics, meshless, numerical model is developed for the simulation of direct chill casting under the influence of a low-frequency electromagnetic field. The model uses mixture-continuum-mass, momentum and energy-conservation equations to simulate the solidification of axisymmetric aluminium-alloy billets. The electromagnetic-induction equation is coupled with the fluid flow and used to calculate the Lorentz force. The involved partial-differential equations are solved with the meshless-diffuse-approximate method by employing second-order polynomial shape functions and a 13-noded local support. An explicit time-stepping scheme is used. The boundary conditions for the heat transfer involve the effects of hot-top, mould chill and direct chill. The use of a meshless method and the automatic node-arrangement generation made it possible to investigate the complicated flow structures in geometrically complex inflow conditions, including sharp and curved edges, in a straightforward way. A time-dependent adaptive computational node arrangement is used to decrease the calculation time. The model is demonstrated by casting an Al-5.25wt%Cu aluminium alloy billet with a radius of 120 mm. Results on simplified and realistic inflow geometry are considered and compared. The effect of the low-frequency electromagnetic force on the temperature, liquid fraction and fluid flow are investigated under different current densities and frequencies.     

The effect of variable viscosity on MHD viscoelastic fluid flow and heat transfer over a stretching sheet

An analysis has been carried out to study the momentum and heat transfer characteristics in an incompressible electrically conducting non-Newtonian boundary layer flow of a viscoelastic fluid over a stretching sheet. The partial differential equations governing the flow and heat transfer characteristics are converted into highly non-linear coupled ordinary differential equations by similarity transformations. The effect of variable fluid viscosity, Magnetic parameter, Prandtl number, variable thermal conductivity, heat source/sink parameter and thermal radiation parameter are analyzed for velocity, temperature fields, and wall temperature gradient. The resultant coupled highly non-linear ordinary differential equations are solved numerically by employing a shooting technique with fourth order Runge–Kutta integration scheme. The fluid viscosity and thermal conductivity, respectively, assumed to vary as an inverse and linear function of temperature. The analysis reveals that the wall temperature profile decreases significantly due to increase in magnetic field parameter. Further, it is noticed that the skin friction of the sheet decreases due to increase in the Magnetic parameter of the flow characteristics.     

Hiemenz flow and heat transfer of a third grade fluid

The laminar flow and heat transfer of an incompressible, third grade, electrically conducting fluid impinging normal to a plane in the presence of a uniform magnetic field is investigated. The heat transfer analysis has been carried out for two heating processes, namely, (i) with prescribed surface temperature (PST-case) and (ii) prescribed surface heat flux (PHF-case). By means of the similarity transformation, the governing non-linear partial differential equations are reduced to a system of non-linear ordinary differential equations and are solved by a second-order numerical technique. Effects of various non-Newtonian fluid parameters, magnetic parameter, Prandtl number on the velocity and temperature fields have been investigated in detail and shown graphically. It is found that the velocity gradient at the wall decreases as the third grade fluid parameter increases.     

The numerical modelling of DC electromagnetic pump and brake flow

The interaction of an externally imposed magnetic and electric field on the laminar flow of a conducting fluid in a channel is studied using computational techniques. The Navier-Stokes equations and the equations describing the electromagnetic field are solved simultaneously in a single control volume-type computational fluid dynamic code, in a moderate Hartmann number and interaction parameter regime. The flow considered is two-dimensional, with an imposed magnetic field acting in the third dimension over the central region of the channel and decaying exponentially in the remainder. A pair of electrodes placed at right angles to the magnetic field exercises control over the resultant Lorentz force and hence the velocity profile shape. This configuration has application in direct-current electromagnetic pumps or, conversely, electromagnetic brakes. The initial parabolic flow profile acquires an M-shape / W-shape mode in the magnetic field fringe regions, corresponding to a pump / brake. A novel coupled procedure is described to model magnetohydrodynamic phenomena and is used to explore the effects of the Reynolds number, interaction parameter, and applied voltage on the pump / brake configuration.     

Three‐dimensional solidification with two possible crystallization states: Existence of solutions with flow in the melt

In this paper we discuss the existence of solutions of a system of nonlinear and singular partial differential equations constituting a phase field model with convection for non‐isothermal solidification/melting of certain metallic alloys in the case where two different kinds of crystallization are possible. Each one of these crystallization states is described by its own phase field, while the liquid phase is described by another one. The model also allows the occurrence of fluid flow in non‐solid regions, which are a priori unknown, and then we have a free‐boundary value problem. Thus, the model relates the evolutions of these three phase fields, the temperature of the solidification/melting process and the fluid flow in non‐solid regions. Copyright © 2009 John Wiley & Sons, Ltd.     

Computation of dilute two-phase flow in a pump

This paper is a report on a joint project between academia and industry which is concerned with computation of dilute two-phase flow through a pump in turbulent condition. The flow field for the continuous phase is computed using the Reynolds averaged Navier–Stokes equations together with mixing length turbulence modeling. The dispersed phase is treated using the Lagrangian approach by tracking it's trajectory along which the information is passed. It is found that the bubbles and small solid particles flow out of the chamber (between the rotating impeller and the casing wall) with the conveying fluid. The solid particles of relatively bigger sizes accumulate at the low pressure zones near the cashing wall or the rotating shaft.     

Biomagnetic viscoelastic fluid flow over a stretching sheet

Of concern in this paper is an investigation of biomagnetic flow of a non-Newtonian viscoelastic fluid over a stretching sheet under the influence of an applied magnetic field generated owing to the presence of a magnetic dipole. The viscoelasticity of the fluid is characterised by Walter’s B fluid model. The applied magnetic field has been considered to be sufficiently strong to saturate the ferrofluid. The magnetization of the fluid is considered to vary linearly with temperature as well as the magnetic field intensity. The theoretical treatment of the physical problem consists of reducing it to solving a system of non-linear coupled differential equations that involve six parameters, which are solved by developing a finite difference technique. The velocity profile, the skin-friction, the wall pressure and the rate of heat transfer at the sheet are computed for a specific situation. The study shows that the fluid velocity increases as the rate of heat transfer decreases, while the local skin-friction and the wall pressure increase as the magnetic field strength is increased. It is also revealed that fluid viscoelasticity has an enhancing effect on the local skin-friction. The study will have an important bearing on magnetic drug targeting and separation of red cells as well as on the control of blood flow during surgery.     

Fluid flow over a thin deformable porous layer

The flow of a viscous fluid over a thin, deformable porous layer fixed to the solid wall of a channel is considered. The coupled equations for the fluid velocity and the infinitesimal deformation of the solid matrix within the porous layer are developed using binary mixture theory, Darcy's law and the assumption of linear elasticity. The case of pure shear is solved analytically for the displacement of the solid matrix, the fluid velocity both in the porous medium and the fluid above it. For a thin porous layer the boundary condition for the fluid velocity at the fluid-matrix interface is derived. This condition replaces the usual no slip condition and can be applied without solving for the flow in the porous layer.     

Influence of radiation on MHD free convection from a vertical flat plate embedded in porous media with thermophoretic deposition of particles

Magneto-hydrodynamics and thermal radiation effects on heat and mass transfer in steady laminar boundary layer flow of a Newtonian, viscous fluid over a vertical flat plate embedded in a fluid saturated porous media in the presence of the thermophoresis particle deposition effect is studied in this paper. The governing equations are transformed by special transformations. Brownian motion of particles and thermophoretic transport are considered in the flow equations. The magnetic field is considered to be applied. Rosseland approximation is used to describe the radiative heat flux in the energy equation. The resulting similarity equations are solved numerically by the fourth-order Runge–Kutta method with shooting technique. Many results are obtained and representative set is displayed graphically to illustrate the influence of the various parameters on the wall thermophoretic deposition velocity, concentration, temperature and velocity profiles.     

Mathematical and physical modelling of steel flow and solidification in twin-roll/horizontal belt thin-strip casting machines

Near-net-shape casting technology is one of the most important research areas in the iron and steel industry today. Driving forces for the development of this technology include a reduction in the number of operations needed for conventionally produced strip. This is especially true of hot rolling operations. The consequent reduction in investment cost when considering new industrial facilities, makes near-net-shape casting operations extremely attractive from a commercial standpoint. Various processes for near-net-shape casting of steel are currently being developed around the world. Of these processes, twin-roll casting machines represent a major area of concentration. We believe that one of the main issues concerning the design of twin-roll casters is the metal delivery system and its effect on the homogeneity of solid shell formation, segregation and surface quality. In the present work, computational fluid dynamics has been used to study different metal delivery systems for twin-roll casting (TRC) and horizontal belt casting (HBC) operations. The METFLO code has been adapted to simulate three-dimensional turbulent fluid flows, heat transfer and solidification in these types of machines. The enthalpy–porosity technique was used to couple fluid flow and solidification phenomena. Two configurations for metal delivery system have been studied to date for TRC: one is a conventional tubular nozzle with horizontal outlets in the directions of the side dams; the other is a slot nozzle with a vertical inlet stream. These simulations have been applied to a pilot caster being studied in Canada, with a roll radius of 0.30 m, producing steel strips with thicknesses ranging from 4 to 7 mm, at relatively low roll speeds ranging between 4 and 12 m/min. Different positions and penetrations of the nozzles in the liquid pool have also been analysed. It has been shown that a tubular nozzle leads to the formation of a non-uniform solid shell along the roll width. In both configurations, a thicker solid shell is formed close to the roll edges, due to the presence of the side dams. In the case of HBC, computations have been made for an extended nozzle metal delivery system, and preliminary water modelling tests carried out to confirm the flow delivery concepts proposed. In addition, instantaneous heat flux measurements to simulated belt substrates have been performed for the horizontal casting of aluminum strip that show somewhat similar characteristics to those measured for steel in the pilot TRC, in terms of transient peaks and decays.     

Flow and heat transfer for a power-law electrically conducting fluid flowing between parallel plates under transverse magnetic field with viscous dissipation

The flow and heat transfer problem with viscous dissipation for electrically conducting non-Newtonian fluids with power-law model in the thermal entrance region of two parallel plates with magnetic field under constant heat flux and constant wall temperature conditions has been studied. The governing equations have been solved numerically using quasilinearization technique and implicit finite-difference scheme. It has been found that the effect of viscous dissipation on heat transfer is quite significant for heating and cooling conditions at the wall.     

Calculation of conjugate heat transfer problem with volumetric heat generation using the Galerkin method

A mathematical model of fluid flow across a rod bundle with volumetric heat generation has been built. The rods are heated with volumetric internal heat generation. To construct the model, a volume average technique (VAT) has been applied to momentum and energy transport equations for a fluid and a solid phase to develop a specific form of porous media flow equations. The model equations have been solved with a semi-analytical Galerkin method. The detailed velocity and temperature fields in the fluid flow and the solid structure have been obtained. Using the solution fields, a whole-section drag coefficient C_d and a whole-section Nusselt number Nu have also been calculated. To validate the developed solution procedure, the results have been compared to the results of a finite volume method. The comparison shows an excellent agreement. The present results demonstrate that the selected Galerkin approach is capable of performing calculations of heat transfer in a cross-flow where thermal conductivity and internal heat generation in a solid structure has to be taken into account. Although the Galerkin method has limited applicability in complex geometries, its highly accurate solutions are an important benchmark on which other numerical results can be tested.     

The effect of suction on boundary layer for rotating flows with or without magnetic field

The effect of suction on the steady laminar incompressible boundarylayer flow for a stationary infinite disc with or without magnetic field, when the fluid at a large distance from the surface of the disc undergoes a solid body rotation, has been studied. The governing coupled nonlinear equations have been solved numerically using the shooting method with least square convergence criterion. It has been found that suction tends to reduce the velocity overshoot and damp the oscillation.     

Heat and mass transfer in MHD non-Darcian flow of a micropolar fluid over a stretching sheet embedded in a porous media with non-uniform heat source and thermal radiation

A mathematical analysis has been carried out to study magnetohydrodynamic boundary layer flow, heat and mass transfer characteristic on steady two-dimensional flow of a micropolar fluid over a stretching sheet embedded in a non-Darcian porous medium with uniform magnetic field. Momentum boundary layer equation takes into account of transverse magnetic field whereas energy equation takes into account of Ohmic dissipation due to transverse magnetic field, thermal radiation and non-uniform source effects. An analysis has been performed for heating process namely the prescribed wall heat flux (PHF case). The governing system of partial differential equations is first transformed into a system of non-linear ordinary differential equations using similarity transformation. The transformed equations are non-linear coupled differential equations which are then linearized by quasi-linearization method and solved very efficiently by finite-difference method. Favorable comparisons with previously published work on various special cases of the problem are obtained. The effects of various physical parameters on velocity, temperature, concentration distributions are presented graphically and in tabular form.     

One-dimensional solidification of pure materials with a time periodically oscillating temperature boundary condition

A finite difference method is used to solve a one-dimensional solidification problem with a periodic boundary condition prescribed at the bottom of the mold of finite thickness. The temperature distributions in the solidified shell and mold, the position of the moving freezing front, and its velocity are evaluated. Analytical results are obtained for the limiting cases and then compared with the numerical predictions to establish the validity of the model and the numerical approach. Interactive effects of the process parameters such as Stefan number of the solidified shell material, the mold thickness, the thermal conductivity and thermal diffusivity between the shell and mold materials on the evolution of the freezing front and its velocity are investigated in detail. The results show that the solidified materials with larger Stefan number grow slower than those with relatively smaller Stefan number. The impact of oscillating mold temperature boundary on the growth of shell thickness is particularly significant at earlier stages of the process and more pronounced for smaller Stefan numbers. Increasing mold thickness or thermal conductivity ratio between the shell and mold materials slows down the evolution of the shell thickness.     

Three-dimensional flow over a stretching surface in a viscoelastic fluid

This article looks at the hydrodynamic elastico-viscous fluid over a stretching surface. The equations governing the flow are reduced to ordinary differential equations, which are analytically solved by applying an efficient technique namely the homotopy analysis method (HAM). The solutions for the velocity components are computed. The numerical values of wall skin friction coefficients are also tabulated. The present HAM solution is compared with the known exact solution for the two-dimensional flow and an excellent agreement is found.     

The influence of heat transfer on peristaltic transport of a Jeffrey fluid in a vertical porous stratum

The peristaltic flow of a Jeffrey fluid in a vertical porous stratum with heat transfer is studied under long wavelength and low Reynolds number assumptions. The nonlinear governing equations are solved using perturbation technique. The expressions for velocity, temperature and the pressure rise per one wave length are determined. The effects of different parameters on the velocity, the temperature and the pumping characteristics are discussed. It is observed that the effects of the Jeffrey number λ₁, the Grashof number Gr, the perturbation parameter N = EcPr, and the peristaltic wall deformation parameter ϕ are the strongest on the trapping bolus phenomenon. The results obtained for the flow and heat transfer characteristics reveal many interesting behaviors that warrant further study on the non-Newtonian fluid phenomena, especially the shear-thinning phenomena. Shear-thinning reduces the wall shear stress.     

Slip at the surface of a sphere translating perpendicular to a plane wall in micropolar fluid

The Stokes axisymmetrical flow caused by a sphere translating in a micropolar fluid perpendicular to a plane wall at an arbitrary position from the wall is presented using a combined analytical-numerical method. A linear slip, Basset type, boundary condition on the surface of the sphere has been used. To solve the Stokes equations for the fluid velocity field and the microrotation vector, a general solution is constructed from fundamental solutions in both cylindrical, and spherical coordinate systems. Boundary conditions are satisfied first at the plane wall by the Fourier transforms and then on the sphere surface by the collocation method. The drag acting on the sphere is evaluated with good convergence. Numerical results for the hydrodynamic drag force and wall effect with respect to the micropolarity, slip parameters and the separation distance parameter between the sphere and the wall are presented both in tabular and graphical forms. Comparisons are made between the classical fluid and micropolar fluid.