Modern capabilities of mathematical modelling make it possible to perform scientific research and engineering calculations of physical processes and technical systems via high-performance electronic computation. Such an approach to the research and the design allows us to find the optimal parameters of equipment and devices within the shortest possible period of time. Moreover, mathematical modelling provides the possibility of studying of the nature of the process in aggressive environments. Also, it helps to identify the critical states of the system and the interrelationships of parameters for the development of automatic control systems as well as to conduct preliminary and final calculations for the development of laboratory and experimental-industrial equipment.
Qualitative mathematical modelling is directly linked to physical modelling and experimentation, however, even carrying out preliminary numerical simulation, allows to reduce the range of investigated parameters and variations of the system significantly and, as a result, to reduce time and material costs. In metallurgy, mathematical modelling becomes the only possible research tool, since most metals in liquid state have a high temperature and chemical aggressiveness for the work of the researcher and measuring equipment.
For more than 30 years of scientific and project activities RPC Magnetic hydrodynamics Ltd. has accumulated a unique practical and theoretical experience of electro-metallurgical processes researching. This experience made it possible to develop, implement and test the universal mathematical models of the melting-casting equipment, MHD-equipment and other equipment. Special analytical methods for calculating, modelling and designing of MHD-devices, proprietary algorithms and programs for two-way coupling of commercial numerical calculation programs, considering the peculiarities of metallurgical processes are the key capabilities and skills of company's experienced team. RPC Magnetic hydrodynamics Ltd. specialists regularly participate in the R&D works, and also in performing mathematical modelling of a full range of physical processes.
Technological processes multidisciplinary calculations with electromagnetic field usage. These calculations are made by the means of internal and external integration of various numerical modelling software and own mathematical modelling.
Formation of the crystallization front of the ingot during casting into an electromagnetic crystallizer and corresponding analysis of the power spectrum of turbulent pulsations near the phase transition zone
Dynamics of the crystallization front formation during casting into an electromagnetic crystallizer
Process of titanium melting in electromagnetic field
Analytical and numerical models of physical processes and technical systems, algorithms for automatic construction, calculation, analysis and optimization of devices, implemented on the basis of commercial and proprietary software are used for. We have developed our own internal and external software tools for two-way coupling of various complexes of numerical simulation of electromagnetic, thermohydrodynamic and other related technological processes, taking into account the peculiarities of their mutual influence.
Calculations are performed on a high-performance computation cluster. RPC Magnetic hydrodynamics engineers use following licensed CAE calculations:
Each new mathematical model of a technical system, in the absence of experimental or verified theoretical data, requires confirmation of reliability and, in some cases, refinement and search for auxiliary or correction coefficients and parameters. Thus, during new equipment designing mathematical modelling is accompanied by the creation of a similar physical model of the system to verify correctness of the mathematical model.
0n the 15th of September 2016 within the framework of the international scientific and educational summer school for students and graduate students "Electrotechnology in Metallurgy, from Idea to Realization", conducted by the SFU Department of Electrotechnology and Electrical Engineering, the educational laboratory for physical modelling of MHD processes in metallurgy was opened with the support of the RPC Magnetic Hydrodynamics Ltd. The laboratory demonstrates MHD phenomena in various devices of metallurgical purpose, equipped with a modern system of digital measurement of electro-physical magnitudes and visualization. In particular, the laboratory presents 7 physical models of MHD systems developed and implemented by the company in practice: crucible and channel furnace with controlled molten metal circulation, conduction MHD pump, liquid heart MHD-stirrer, an MHD stirrer with a transverse magnetic flux, distributed MHD-stirrer, MHD-vortex. The laboratory was highly appreciated by the guests of the scientific school, and its use in the teaching process for the preparation of undergraduate and graduate students of electrotechnology specialities (13.03.02.11 and 13.04.02.07) has been started. The laboratory is regularly improved and supplemented as the company develops new technologies and equipment.
Advanced developments, before mass introduction into the industry, are tested and reworked at the RPC Magnetic hydrodynamics Ltd. experimental-industrial department. Small-scale production is carried out by this department using innovative technological processes and equipment to ensure energy, resource saving and achieving unique physical and mechanical characteristics of products.