The product quality and production efficiency are extremely important to competitively participate on demanding international markets, especially in the field of steel manufacturing. To achieve such quality in a consistent manner, one needs to understand and to master all the steps in the manufacturing process, for which the numerical models are especially convenient. In the project we establish a prototype of a simulation environment for the case of manufacturing chain of top Slovenian steel manufacturer Štore Steel. This will allow the use of numerical models along the entire production chain in a way that coherently connects the numerical models of individual production steps and allows the traceability of product properties. The project represent a logical continuation of our previous, successfully completed applied research project: “L2-6775 Simulation of industrial solidification processes under influence of electromagnetic fields” and “L2-9246 Multiphysics and multiscale numerical modelling for competitive continuous casting” and related EU projects. With the help of the acquired knowledge, we equipped the partner’s large investments in the new steel and rolling mill with advanced numerical models and encouraged the digital transformation of the company towards Industry 4.0. The purpose of the proposed project is to further develop models within the entire process chain of high quality steels production for the understanding, prediction and elimination of production defects such as: macrosegregation, inclusions, shape distortions, porosity, hot tearing, reduced surface quality and cracks. The first goal is to develop a modular multiscale through process model, based on travelling slice assumption for the process chain from continuous casting to heat treatment. The slice will include thermal, concentration, mechanical, and microstructure models. From the combination of these modules quality and defect indicators will be extracted. We will complement the already existing models for continuous casting and hot rolling built on this principle with the modules connecting these two processes and extending them to heat treatment, thus establishing a complete process model. In this model a balance between the physical fidelity and the computing time will be considered. The model will allow to establish the basic relations between the energy consumption, macroscopic fields, microscopic fields and properties. The second goal is to develop the missing and to improve the existing physical modules without a particular constraint on the computing time. These modules will run on a highperformance platform. The missing models will include radiation heat transfer and fracture mechanics, and the improved models will include three-dimensional microstructure models. Artificial intelligence will be used to adapt simplified models with detailed models and for multi-objective optimization in terms of energy consumption, efficiency, and product quality. The third goal is experimental analysis of inclusions based on the water model for continuous casting, developed in the previous project, and experimental analysis of microstructure, product properties and defects after each process step for the purpose of validation. Solution procedures in the simulation system will be further developed on the basis of our award-winning innovative meshless computing technologies, concepts of continuum mechanics at the macroscopic level, point automata concepts at the mesoscopic level and the phase field concept at the microscopic level. Numerical implementation will take advantage of the parallel computing capabilities of modern workstations and supercomputers. The expected effects of the new knowledge are improved quality, enhanced process capabilities and productivity. The results will be implemented in production, published in top impact factor journals in the field and presented as keynotes at large international meetings.
Domestic research projects
Research projects (co)funded by the Slovenian Research Agency.
- Member of University of Ljubljana: UL Faculty of Mechanical Engineering
- Project code: L2-3173
- Project title: Advanced simulation and optimization of the entire process route for production of topmost steels
- Period: 01.10.2021 - 30.09.2024
- Range on year: 1,57 FTE
- Head: prof. dr. Božidar Šarler
- Research activity: Engineering sciences and technologies
- Research Organisation: Link
- Researchers: Link
- Citations for bibliographic records: Link
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