Influence of Processing Parameters on Flow Behaviour of Ultra-Large-Section Beam Blank Continuous Casting Mould

The complex cross-sectional shape of oversized beam blanks and the size effect of ultra-large-section beam blanks create severe issues related to the surface and internal quality of the castings. To ensure quality and control in the production of ultra-large-section beam blanks, a numerical and physical model of molten steel flow in the three-port submerged entrance nozzle (SEN) mould, with section dimensions of 1300 × 510 × 140 mm, was established. This model was created using numerical simulations and NSGA-II genetic algorithm optimisation, and the impact of the casting speed and SEN immersion depth on the mould’s flow behaviour was investigated. The results showed that a deeper SEN immersion depth resulted in, a greater impact depth of the molten steel, and the surface flow velocity decreased. Both the impact depth and the surface flow velocity of the molten steel increased with increasing casting speed. The physical simulation and numerical simulation of the molten steel flow form and flow velocity distribution in the mould were in good agreement with each other, thus verifying the accuracy of the numerical simulation. The process parameters derived from this study were all within an appropriate range, which can help to improve the quality of continuously cast beam blanks. This also provides guidance for selecting optimal parameters for actual continuous casting production processes.