Abstract

A transient three-dimensional (3D) coupled model is developed to investigate the melting and rotation of the solid electrode during the electroslag remelting (ESR) process. The large eddy simulation (LES) method is utilized to model the multiphase flow. The slag/metal interface is precisely tracked utilizing the volume of fluid (VOF) approach with an adaptive mesh refinement strategy. The model pays specific attention to the shape evolution of the electrode tip, as well as the formation and motion of droplet under different electrode rotating speeds. The accuracy of the model is validated by an additional transparent experiment. As the electrode rotates, the centrifugal force pushes the randomly dispersed faucets underneath the electrode outwards until reaching the periphery. The electrode rotation flattens the electrode tip, reducing the horizontal deviation of its profile by up to 69.9 pct compared to a static electrode. As the electrode rotating speed increases from 0 to 60 rpm, the thickness of liquid metal film decreases from 0.91 to 0.63 mm, while the equivalent diameter of droplets decreases from 12.90 to 11.77 mm. The electrode rotation increases the specific surface area, dramatically improving the removal efficiency of inclusions and harmful elements. Moreover, productivity reached a maximum of 21.56 pct at a rotating speed of 60 rpm without increasing power input.

中文翻译：

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电渣重熔过程电极熔化与旋转三维多物理场耦合模型

摘要

开发了瞬态三维 (3D) 耦合模型来研究电渣重熔 (ESR) 过程中固体电极的熔化和旋转。利用大涡模拟（LES）方法对多相流进行建模。利用流体体积 (VOF) 方法和自适应网格细化策略精确跟踪炉渣/金属界面。该模型特别关注电极尖端的形状演变，以及不同电极旋转速度下液滴的形成和运动。该模型的准确性通过额外的透明实验进行了验证。当电极旋转时，离心力将电极下方随机分散的水龙头向外推动，直到到达外围。电极旋转使电极尖端变平，与静态电极相比，其轮廓的水平偏差最多减少 69.9%。随着电极转速从0 rpm增加到60 rpm，液态金属膜的厚度从0.91 mm减小到0.63 mm，而熔滴的当量直径从12.90 mm减小到11.77 mm。电极旋转增加了比表面积，大大提高了夹杂物和有害元素的去除效率。此外，在不增加功率输入的情况下，在转速为 60 rpm 时，生产率最高达到 21.56%。