WINCPS technical description
Rev. 1
September 2002
WINCPS System
Casting Process Simulator for Windows
Product position
The Casting Process Simulator is a system, based on a sophisticated mathematical model, used for
investigate the cooling process on billet and bloom continuous casting machines. It is applicable either on
square product or on rectangular ones.
Features and benefits
The WINCPS simulate the cooling process of the product, at fixed casting speed, from the mould to
the metallurgical length.
It takes into account the effects of mould cooling, secondary cooling and free (air) cooling applied to
the billet.
The cooling calculation model is customised according to the caster geometry, mould tube type,
length and lubrication applied, secondary (spray) cooling details and process main data.
The WINCPS shall be run for all the steel grades, in facts the system is provided with data input fields
for fine set-up of carbon contents, alloying and pouring temperature data.
The WINCPS mathematical model gives the following theoretical results:
K-factor data from mould to metallurgical length.
Surface temperature data from mould to metallurgical length.
Internal temperature data from mould to metallurgical length.
Shell thickness from mould to metallurgical length.
WINCPS is a helpful system for the process specialist, running the model he should do the following:
Investigate the actual casting process parameters: metallurgical length, surface and internal
temperature trends etc…
Refine / optimise actual casting process parameters: check the results changing cooling intensity and
other process parameters in order to get better product quality.
Increase productivity on actual casting process parameters: check the results slowly increasing the
casting speed and cooling intensity.
Define new casting process parameters when a new steel grade or a new billet size is adopted.
Data export to other platforms
From the WINCPS is possible to export all the resulting data of the mathematical model to the Microsoft
Excel software.
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WINCPS technical description
Rev. 1
September 2002
Overview
Data input
On the main window are
available some input data
fields in order to set up the
main parameters of the
caster, the type of steel
grade, the pouring
temperature, the mould type
and length etc…
A dedicated window is foreseen in order to
set-up the secondary (spray) cooling zones.
On the spray cooling data input window is
possible to define the number of cooling
zones, the geometry of each zone, the spray
nozzle type and the working pressure of
them.
Load and save windows are available, in order
to retrieve or save all the data inputs of a
project already set.
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WINCPS technical description
Rev. 1
September 2002
Calculation model
When all the input parameters has been
set-up, is the time to start running the
calculation model of the cooling
simulator.
The model subdivide the billet in small
parts, according to the billet size and the
casting speed.
Data output – graphical simulation
After the cooling calculation model has performed the
complete calculation, from mould to metallurgical length,
it is possible to call the data visualisation window.
On the data visualisation window are shown the following
data:
 Pouring temperature
 Solidification temperature
 Casting speed
 Solidification time
 Solidification length
 K-factor at metallurgical length
 Surface temperature factor at metallurgical length
 Billet cooling rating at metallurgical length
A pushbutton on the screen permits to start the graphical
simulation of the cooling process. The simulation proceeds
step by step from mould to metallurgical length, showing
the internal and surface temperature maps, the shell
thickness and the place in the caster geometry of each
step shown.
The following step by step data are also mentioned:
 Calculation time
 Meniscus distance
 K-factor
 Shell thickness
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WINCPS technical description
Rev. 1
September 2002
Data output – graphs
After the cooling calculation model has performed the complete calculation, from mould to metallurgical
length, it is possible to call the graphs window from the data visualisation window.
On the graphs window are shown the following graphs:
 K-factor from mould to metallurgical length
 Shell thickness from mould to metallurgical length
 Diagonal temperatures from mould to metallurgical length
 Surface temperatures (edge and centre face) from mould to metallurgical length
K-factor
Shell thickness
Diagonal temperatures
Surface temperatures
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WINCPS technical description
Rev. 1
September 2002
Data output – export data to Microsoft Excel
After the cooling calculation model has performed the complete calculation, from mould to metallurgical
length, it is possible to save all the results to excel file.
In this way the excel file shall be customised in order to analyse in detail the results.
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WINCPS technical description
Rev. 1
September 2002
Specifications
The Casting Process Simulator system is composed by the following parts:
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

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Personal computer, desktop type
Monitor, keyboard, mouse and accessories
Operating system
Microsoft office
WINCPS software
The system is delivered ready for use, with all the software mentioned installed on the hard disk.
The WINCPS cooling calculation model is previously customised according to the caster geometry, mould
details and secondary (spray) cooling details of the customer.
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