New electromagnetic variable flow device for slab continuous casting mold: mechanical design and magnetic field analysis

Obtaining a reasonable mold flow field for casting slabs with different sections is challenging by solely modifying the nozzle structure and continuous casting process. Research was conducted on small-sectioned (1000 mm × 220 mm) and large-sectioned (3250 mm × 220 mm) slab continuous casting molds with a fixed nozzle form (concave bottom nozzle, side port inclination angle of 0°). A three-dimensional electromagnetic model is established to analyze the current frequency, installation position, and rotation angle under the active deceleration mode and acceleration mode. The results indicate that, regardless of the deceleration mode for small-sectioned slabs or the acceleration mode for large-sectioned slabs, the magnetic flux density in the mold decreases with increasing current frequency. However, the maximum electromagnetic force initially increases and then decreases, suggesting that both electromagnetic modes have the same optimal current frequency (3 Hz). The optimal mechanical design parameters for the deceleration mode of electromagnetic variable flow device (EM-VFD) with the small-sectioned slab are as follows: installation position Z = 115 mm and rotation angle of 15°, ensuring that the maximum electromagnetic force is applied to the nozzle jet area. For the acceleration mode of the large-sectioned slab EM-VFD, the optimal mechanical design parameters are as follows: Z = 115 mm and rotation angle of 10°, ensuring that the maximum electromagnetic force is applied to 1/4 and 3/4 areas of the wide face. These findings indicate that the new electromagnetic variable flow device, which can actively adjust the flow rate and angle of the steel even under given working conditions, provides the possibility for reasonable control of the mold’s flow field.