698
NUMERICAL SIMULATION OF ELECTROMEGNETIC
CASTING OF ALUMINUM ALLOYS
Abstract:
This work deals with the improvement of surface quality, microstructure of the
aluminum alloy ingot by electromagnetic casting using finite element method with the
help of Ansys program. Magnetic flux density and magnetic flux density gradient are
used as indicators for uniform temperatures distribution and new liquid metal flow.
Two models are simulated in this study; the first one represents a solid cylinder with a
single coil where the effects of current intensity and frequency on the melt metal are
studied. The second model is a hollow cylindrical with outer/inner coils. The effects of
current intensity, due to the interaction between the outer and inner coil are studied.
The results of the first model simulation indicate three stages with the current
increasing. The first one near the center of the ingot enhanced approximately
homogeneous behavior, while the increasing occurs gradually in the second and third
stages. Also with decreasing of frequency the magnetic flux density at the center of
ingot increasing. The second model results of hollow ingot show that the magnetic flux
density increases linearly with outer coil current increasing from (85 – 380) A at the
same inner coil current value, and the homogeneous behavior enhanced in 0.55
outer/inner coil current ratio also illustrates homogeneous behavior at different current
values but with the same ratio.