A numerical model for coupled free surface and liquid metal flow calculation in electromagnetic field

On account of ANSYS Classic, ANSYS Fluent and ANSYS CFX-Post external coupling a new approach for joined simulation of liquid metal flow, free surface dynamics and electromagnetic (EM) field in induction furnaces is developed. The model is adjusted for the case of EM levitation and extended on 3D consideration with application of standard k-ω Shear Stress Transport (SST) or précised Large Eddy Simulation (LES) turbulence description. Calculated steady state free surface shapes of molten metal are compared to other models and experimental measurements in traditional and EM levitation induction furnaces. Calculated free surface dynamics of melt is compared to analytical estimation of free surface oscillation period. Parameter studies performed in ICF and conventional EM levitation setup briefly illustrate capabilities of the model and demonstrate the influence of current, frequency, surface tension and viscosity on free surface dynamics and steady shape of the melt in 2D approximation. Finally, full 3D calculation of free surface dynamics in ICF using k-ω SST and LES turbulence models is performed and the impact of turbulence model on meniscus is discussed.