SIMULATION OF HEAT-TRANSFER AND STRESS-ANALYSIS OF CONTINUOUS-CASTING

Due to high productivity and the ability to cast to a form which could be rolled directly to a final product, continuous casting was selected for analysis and simulation. Three-dimensional finite element was used because of its capability to analyze any type of ingot with arbitrary section. Various types of boundary conditions which occur during the solidification process, as well as temperature dependent material properties were discussed. Two generalized models for heat transfer and stress analysis were developed. The first model, based on variation of heat transfer boundary conditions, was used to predict temperature distribution and solid shell formation. The second model, by considering applied thermal and mechanical loads and enforced displacements on the ingot, was used to calculate the stress distribution within the solid shell. These models provided design engineers with a reliable method of optimizing the casting processes and parameters. The computer results of the temperature distribution compared favorably with the other literature. Application of the temperature history along with other boundary loads and displacements into analysis, determined that the maximum stress occurs at the mold exit, the pinch and bending rolls, and the complete solidification areas. To predict the places with higher chance of crack formation a ratio of calculated stress to von Mises stress was used. The maximum stress ratio was detected at the location of the bending rolls.