Process chain optimization through digital twin technology with casting process simulation in the BMWI research project "SiPro"
S. Koldorf1, E. Shvydkii1, N. Lehnert2
1 - MAGMA Gießereitechnologie GmbH, Aachen, Germany
2 - Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU, Chemnitz, Germany
Digital simulation technology today makes is easily possible to carry out three-dimensional process simulation of the entire continuous casting process. State-of-art simulation tools provide quantitative insights into flow, solidification and stress formation. This includes the entire process, from the tundish and the flow into the mold to the solidifying strand that is withdrawn through the secondary cooling zones. Recent developments in modelling of electromagnetic stirring (EMS) and its impact on the flow behaviour as well as a thermomechanical coupling with simulation of stress development in the strand can also be considered.
The classical use of simulation solutions has evolved to approaches focusing on the optimization of the complete process. Statistical tools such as virtual Design of Experiments allow the performance of systematic virtual experimentation covering the complete process window. In this manner, expensive and energy intensive experimental trials can be avoided and replaced with the digital twin technology of MAGMA CC.
A simulation-based optimization of the process chain to save energy, resources and costs is the main focus in the BMWI project “SiPro”. The degree of digitalization in steelworks and subsequent steel processing companies is increasing significantly, which consequently amplifies the importance of identifying significant process parameters and investigating the effect of parameter changes. Important information about the quality, productivity and energy saving potential of process alternatives can be investigated through virtual experiments. Based on this knowledge, the optimized casting processes are both cost- and energy-efficient, as well as robust with respect to final product quality and its sensitivity to process variations.
By using MAGMA CC and through the development of new interfaces, it is also possible to connect and integrate separated simulation approaches and close the virtual process chain, to include subsequent forming and forging simulations up to the final product performance.
The results are shown for pilot and industrial scale examples of billets and bloom casters. The objective is to realize the full cost and energy saving potential, reduce CO2 emissions as well as improve quality by using digital twin technology during production.
