Analysis of thermomechanical behaviour in billet casting with different mould corner radii

This study investigates the thermomechanical behaviour of steel billet casting with varying mould corner radii to address the challenge of longitudinal crack formation. The central objective is to obtain a quantitative understanding of crack mechanisms and their relationship with corner radii, which is crucial for optimising mould design. A finite element thermal stress model is developed to simulate the thermomechanical state of the solidifying shell during continuous casting. This model is employed to assess temperature distributions, stress, strain, and the intermittent air gap between the casting mould and the solidifying strand, particularly focusing on a steel mould with different corner radii. The predictive capabilities of the model are validated against both analytical solutions and practical trials. The findings reveal that reducing the corner radius significantly decreases crack frequency and alters crack locations, though sharp edges can lead to deformation during subsequent rolling processes. Ultimately, this work contributes to refining design strategies that balance the need for reduced cracking with the integrity of the final cast product.