A three-dimensional coupled mathematical model for steel flow and solidification in a soft-contact EMC (Electro-Magnetic Casting) mold was developed. Non-staggered grid system with BFC (Body Fitted Coordinate) for the steel flow and solidification considering the complex geometry of the electromagnetic mold and the irregular meniscus shape of the melt were used. This mathematical model was applied to investigate the steel flow and solidification, and the effect of electromagnetic parameters on steel solidification in a 100 mm×100 mm square billet soft-contact mold. Numerical results showed that the electromagnetic induction heat mainly affects the distribution of steel temperature at upper part of EMC mold especially in the vicinity of meniscus. Consequently the steel temperature near the free surface is increased distinctly, and the hot-top condition is formed at the top of mold. It was clearly seen that the solidification start point shifts downward under the three-phase point by applying alternative electromagnetic field. As a result, the initial shell thickness gets thinner and the shell length shorter.
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