Optimization design of a new pulsed magnetic field furnace head box for copper alloy casting based on COMSOL

This study employs COMSOL Multiphysics to model the electromagnetic field and melt flow field in a novel pulsed magnetic field furnace head box developed for copper alloy casting. The simulations indicate a relatively weak magnetic induction intensity in the central region of the head box. Furthermore, it is observed that the melt flow rate at the central outlet at the bottom of the head box is relatively high. To address these issues, various types of baffles within the head box, including cross-sectional and V-shaped structures, are designed. Their characteristics, such as dimensions, placement, and the opening angle of the V-shaped baffle, are refined through simulation trials. An analysis is conducted of the impact of pulsed magnetic field treatment on melt volume, flow characteristics, and internal pressure distribution. The optimal solution identified is the V-shaped baffle. Two limiting states of the V-shaped baffle are proposed on the basis of numerical simulations, considering specific placement positions within the box together with empirical formulas. The V-shaped baffle facilitates uniform flow of molten copper toward the electromagnetic field’s effective working zone, enhancing processing efficiency. Additionally, it boosts the melt flow rate in stagnant regions near the head box periphery. This configuration enhances electromagnetic treatment efficiency, leading to an overall improvement in the casting quality of furnace head boxes in groups of electromagnetic-equipped copper melting furnaces.