Numerical Modeling of Free Surface Dynamics of Melt in an Alternate Electromagnetic Field. Part II: Conventional Electromagnetic Levitation

By means of external coupling between electromagnetic (EM) problem in ANSYS and hydrodynamic problem in FLUENT, a numerical model for the liquid metal free surface flow in an alternate EM field has been developed and verified in the first part of the article. Volume of Fluid (VOF) algorithm has been used for tracking of free surface. In this work, improved performance of the model is presented. General validation of the VOF algorithm is performed by comparison of the calculated free oscillations of the liquid column to its analytical solution. The 3D/VOF calculation of coupled EM field and free surface flow with Large Eddy Simulation turbulence description for the first time is applied for modeling of conventional EM levitation. Calculation results are compared with 2D/VOF and 3D/VOF models that use less precise k–ε and k–ω SST turbulence formulations. Obtained time-averaged droplet shapes are used for single-phase flow calculations with different turbulence models and free-slip/no-slip velocity conditions at the fixed free surface for validation of the flow. Meanwhile, series of levitation melting experiments are performed for verification of the simulated droplet shapes. In conclusion, parameter impact on the fully developed flow and the levitated droplet shape is discussed.