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Influence of Liquid Core Reduction on Stress-strain

Distribution and Strand Deformation
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in a Thin Slab
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September 2016 · ISIJ International 56(9):1616-1624
DOI:10.2355/isijinternational.ISIJINT-2016-242
Authors:

Li Hongxiang
University of Science and Technology Be…

Wen Zhen Zhu Demian Ruvalcaba

Dag Mortensen
Institute for Energy Technology

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Citations (4) References (29) Figures (16)

Abstract and Figures

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A new numerical model called SteelSim, which is based on the Finite Element Method
(FEM), has been developed in order to investigate the Liquid Core Reduction (LCR)
research
section in a thin slab continuous caster. As a SteelSim application example, the influence
20+ million members
of roll alignment on temperature distribution, solidification, stress-strain distribution and
strand deformation has been studied. The thermo-elasto-viscoplastic constitutive 135+ million publications
equations and the Arbitrary Lagrangian Eulerian (ALE) kinematic description for the
conservation equations were calculated in the SteelSim model. From the results, it can 700k+ research projects
be seen that the roll configuration: (a) symmetrical alignment of rolls with LCR, (b)
asymmetrical alignment of rolls with LCR, and (c) symmetrical alignment without LCR, Join for free
has an influence on the local stress-strain distribution and thus local strand deformation,
which in turn affects the evolving shape profile of the narrow face. Eventually, the
SteelSim model can be utilized for determining optimal roll configurations and casting
conditions for specific steel grades in order to avoid the formation of critical casting
defects, such as: excessive bulging, macrosegregation, cracking etc., which may lead to
poor product quality or even total failure of the casting process due to a breakout. The
results presented here may allow us to further analyze and validate the model with
actual plant casting data.

+11

. The constitutive The . The casting Cooling zones at . The thermo-

parameters of… configurations i… machine… the rolls section. physical…

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ISIJ International, Vol. 56 (2016),

ISIJ International,
No. 9 Vol. 56 (2016), No. 9, pp. 1616–1624

Influence of Liquid Core Reduction on Stress- strain Distribution

and Strand Deformation in a Thin Slab Caster

1) 1) 2) 3) 2)
Hong Xiang LI, * Wen Zhen ZHU, Demian RUVALCABA, * Dag MORTENSEN, Dirk van der PLAS,
3) 1,2)
Hallvard Gustav FJAER and Lin Zhong ZHUANG

1) State Key Laboratory for Advanced Metals and Materials, University of Science and Technology Beijing, Beijing, 100083
China. 2) Research & Development, Tata Steel, 1970 CA IJmuiden, Netherlands.
3) Computatonal Materials Processing Department, Institute for Energy Technology, N-2027 Kjeller, Norway.

(Received on April 19, 2016; accepted on May 26, 2016)

A new numerical model called SteelSim, which is based on the Finite Element Method (FEM), has been
developed in order to investigate the Liquid Core Reduction (LCR) section in a thin slab continuous caster.
As a SteelSim application example, the influence of roll alignment on temperature distribution, solidifica-
tion, stress-strain distribution and strand deformation has been studied. The thermo-elasto -viscoplastic
constitutive equations and the Arbitrary Lagrangian Eulerian (ALE) kinematic description for the conserva-
tion equations were calculated in the SteelSim model. From the results, it can be seen that the roll con-
figuration: (a) symmetrical alignment of rolls with LCR, (b) asymmetrical alignment of rolls with LCR, and
(c) symmetrical alignment without LCR, has an influence on the local stress-strain distribution and thus
local strand deformation, which in turn affects the evolving shape profile of the narrow face. Eventually,
the SteelSim model can be utilized for determining optimal roll configurations and casting conditions for
specific steel grades in order to avoid the formation of critical casting defects, such as: excessive bulging,
macrosegregation, cracking etc., which may lead to poor product quality or even total failure of the casting
process due to a breakout. The results presented here may allow us to further analyze and validate the
model with actual plant casting data.

KEY WORDS: finite element method; continuous casting modelling; liquid core reduction; roll alignment;
solidification.

heat ux, roll misalignment, unstable uid ow conditions

1. Introduction
and inadequate casting speeds can induce casting defects in
The thin slab continuous casting technology has achieved the strand such as: surface cracks, hot tearing, excess bulg-
great research focus due to the increasing industrial require- ing, breakouts and irregular shaped narrow faces, especially
ments, such as: lower production costs, larger energy sav- when considering the large amount of deformation that
ings and higher production efciency, since this casting can be achieved at the LCR section in the thin slab casting
technology can be more suitable for achieving these require- process.5,6)
ments as compared with the conventional casting process.1,2) In recent years, having computational costs decreasing
In thin slab casting, the Liquid Core Reduction (LCR) is a and more powerful modeling packages available, applying
critical section which allows fast strand reduction from the mathematical models to understand the complicated con-
initial thickness, achieved at the mould exit, down to the tinuous casting process is becoming an accepted approach.7)
nal thickness requirement. The funnel-shaped mould, in a Thus, the numerical simulation of temperature distribution,
thin slab caster, allows for the placement of a larger nozzle solidication, stress-strain distribution and strand deforma-
which facilitates higher metal inow, thus leading to higher tion during continuous casting has been the focus of many
casting speeds and production rates.3,4) High casting veloci- studies, which are of great interest to help the casting engi-
ties require good control of the rolling process in the Liquid neers and operators for optimizing their casting parameters
Core Reduction section of a thin slab caster, whereby the such as: casting speed, cooling conditions, etc. For example,
mass ow needs to be in balance with the withdrawing roll- Ren and Wang8) analyzed the inuence of bulging and strain
ing forces which provide the deformation of the strand. It on the solidifying shell of a continuously cast strand with
is very important to study the local deformation of the solid the thermo-elastic bending theory. It has been shown that
shell during the LCR process, because non-uniform local negative bulging may occur in the caster due to changes in
roll pitch and roll misalignment. Lin and Thomas showed
* Corresponding author: E-mail: hxli@skl.ustb.edu.cn, the effects of roll pitch and misalignment on the strand
demian.ruvalcaba-jimenez @tatasteel.com deformation with a two dimensional model based on the
DOI: http://dx.doi.org/10.2355/isijinternational.ISIJINT-2016-242 Finite Element Method (FEM) code ABAQUS.9) As a result,

© 2016 ISIJ 1616

ISIJ International, Vol. 56 (2016), No. 9

it was found that roll misalignment was a dominant factor Where v and K are the kinematic viscosity of the liquid
in determining the shell deformation. Ha et al.10) analyzed and the permeability of the mush, respectively. M is a num-
the inuence of casting speed, cooling conditions and roll ber which forces the mixture ow eld to be equal to the
pitch on bulging deformation in a 3-D FEM model by using solid velocity in the solid region. Tl and Ts are the liquidus
elasto-plastic constitutive equations including creep. Zhang and solidus temperatures, respectively. The permeability
et al.11) presented a thermo-mechanical model considering K is dependent on the morphology of the mush. It is here
roll arrangement to predict the 3-D temperature distribution numerically described by the Kozeny-Carman equation:14)
and strand deformation. Triolet et al.12) conducted transient
(g )
3
l
thermo-mechanical modeling of the continuous casting pro- K = K0 ............................(3)
cess using a software tool called TherCast and investigated
the effects of roll arrangement and heat transfer on strand
( 1 −g ) l 2

deformation, demonstrating that a roll misalignment may
strongly disturb the bulging prole.
Recently, a new numerical FEM model called SteelSim
has been developed by the Norwegian Institute for Energy
Technology in cooperation with Tata Steel in order to bet-
ter understand the deformation of the strand during thin
slab casting. The model uses the thermo-elasto-viscoplastic
constitutive equations and employs the ALE algorithm in
order to realize the displacement and vertical expansion of
the grid (simulating the dynamic deformation and vertical
displacement during continuous casting). This study shows
the SteelSim numerical simulations of temperature distribu-
tion, solidication, stress-strain distribution and mechanical
deformation of the solid shell and mushy zone (i.e. semi-
solid solidication transition region) for a low-carbon steel
0.045C, 0.2Mn (wt%) considering three roll congurations:
(a) symmetrical alignment of rolls with LCR, (b) asym-
metrical alignment of rolls with LCR, and (c) symmetrical
alignment without LCR. The study focuses on the deforma-
tion of the narrow face shape, since the bulging of the non-
constrained narrow face is more evident and can serve as a
measurable characteristic for validating the model with actual
plant data. Eventually, the model can be used for determin-
ing the optimal casting parameters for different steel grades.
2. SteelSim Numerical Model
2.1. Heat Transfer and Fluid Flow
The model for heat transfer and uid ow is based on a
continuum mixture model13) for the solid-liquid material.
A Darcy force is used in the mixture momentum equations
which accounts for the interfacial friction due to the differ-
ent velocities of the solid and the liquid. The current mixture
model is simplied by neglecting the local solidication
shrinkage and the solute transport caused by gradients in
chemical composition. Thermal convection is included by
the Boussinesq approximation. The mixture velocity is
dened by:
ui = gl uli + gs usi .............................. (1)
where g l, g s are the volume fractions of the liquid and the
solid phases respectively, and uli , uis are the volume aver-
aged velocities of the liquid and the solid phases, respec-
tively. The Darcy force is given as follows:
 0 for
 2.3. Stress-strain Distribution
 ν s
Si = 
K
( )
ui − u i for

M (u − u )
 from viscoplastic deformation. During strand solidication,

s
i i
K0 numerically describes the inuence of the structure
on permeability. In this case, the secondary dendrite arm
spacing DAS is considered for this estimation as follows:
( DAS )2
K0 = ............................... (4)
180
The buoyancy force fi is given by:
∆ρ
fi = gi .................................. (5)
ρ0
where Δ ρ is the density difference from the liquidus tem-
perature, ρ0 and gi and are the constant density and the
acceleration of gravity, respectively. The mass and momen-
tum conservation equations are solved as follows:
∂u i
= 0 .................................... (6)
∂x i
∂ui ∂ui 1 ∂p ∂ ∂ui
+ ( uj − ωj ) =− + ν + fi + Si .... (7)
∂t ∂x j ρ0 ∂xi ∂x j ∂xj
where p and ω are the pressure and the velocity of the
computational nodes, respectively. The mixture energy
equation is:
∂h ∂
ρ + ρ (u j − ω j ) ∂h = λ ∂T .............. (8)
∂t ∂x j ∂x j ∂ xj
where h, T and λ are the mixture enthalpy, temperature and
thermal conductivity, respectively. Free solid material in the
mush is neglected, and it is assumed that the whole solid
is connected to the dendritic structure. More details on the
model and the numerical solution techniques of the equa-
tions presented here can be found in Ref. 15).
2.2. Expanding Geometry
The current model contains three sub-domains within
the calculated strand domain: the Eulerian, the Expansion,
and the Lagrangian sub-domains. The Arbitrary Lagrangian-
Eulerian (ALE) numerical approach was used for simulat-
ing the continuous casting process by having an expanding
region in the Expansion sub-domain and having elements
continuously added to the Lagrangian lower domain follow-
ing the specied casting speed for the vertical displacement
of the nodes. Further details of the ALE description can be
found elsewhere in Refs. 16)–18).
T > Tl
Ts < T < Tl .... (2)
The thermo-elasto-viscoplastic constitutive equations
were used in this study without considering heat produced
for T < Ts
the total strain is divided into elastic ε es , viscoplastic ε ps ,

1617 © 2016 ISIJ

ISIJ International, Vol. 56 (2016), No. 9

and a thermal part ε Ts , thereby having the formulation as

follows:19)
ε = ε es + εsp + εTs ............................. (9)
The constitutive equation for elasticity describes the inu-
ence of elastic strain ε es on the stress σ. This is given by the
Hook’s generalized law, which is written in the form:
σ = D(T )⋅ ε es .............................(10)
where the Young’s modulus and the Poisson’s ratio are
entered into the matrix D as a function of temperature.19)
The Young’s modulus E and the Poisson’s ratio v as a
function of temperature are listed in Table 1. Intermediate
values are obtained accordingly by linear interpolation.
The thermal strain component is described by Bellet and
Fachinotti as an integral:20)
1 T coh
ε = − ∫ β T (T )dT I⋅ ..................... (11)
T
s optimal distribution of stresses in the solid shell is required
3 T
where the volumetric thermal expansion coefcient βT is set
as constant, and the mechanical coherency temperature Tcoh,
for the current steel, is considered as 1 520°C.
Plastic ow is determined by the constitutive equations
applied earlier by Fjær and Mo,19) whereby the ow stress
σ is determined as •
a function of temperature T and visco-
plastic strain rate ε p
•
σ = F (T ) ⋅(φ 0 +φ )n (T ) ⋅(ε p )m T(
3. Geometry Model, Thermo-physical Properties and
Boundary Conditions
3.1. Geometry
In this study, the SteelSim model was set-up for simulat-
ing the temperature distribution, solidication, stress-strain
distribution and strand deformation during continuous thin
slab casting. The main casting parameters, part of the lay-
out of the LCR and strand cooling conditions are based on
data obtained from the Tata Steel thin slab caster located
in IJmuiden, The Netherlands. The submerged entry nozzle
and funnel shape of the actual casting set-up were not con-
sidered in the current model, instead a uid ow with a uni-
form velocity at the metal level inlet was included. For this
study, a rectangular mould geometry was used. The LCR
section is a critical part in the casting process whereby roll-
ing forces inuence the development of the solid shell. An
in order to provide further deformation of the strand without
failure. For this study we only consider the inuence of roll
conguration on the narrow face development at the upper
part of the LCR. In this region, the early solidifying shell
is no longer constrained by the mould walls, thus bulging
at the narrow face, due to the inner ferrostatic pressure, is
the most critical.
Figure 1(a) demonstrates the half-symmetry geometry
)

...............(12)
 dε p , T ≤ T0
dφ = 
 0, T >T 0
where F(T), n(T) and m(T) are nonlinear functions of T. F(T)
accounts for the temperature dependence of the ow stress
σ , whereas n(T) and m(T) are the strain hardening exponent
and strain rate sensitivity coefcient, respectively. These
functions can be attained through a tting method from the
measured true stress-strain curves of the steel. The tted
specic values F(T), n(T), m(T) are listed in Table 1. Here,
ϕ0 is assigned a value of 0.0001. Work hardening occurs
bellow the T0 temperature, which in this case is considered
as 1 500°C.

Table 1. The constitutive parameters of low carbon steel.

Young’s
Temperature, F Poisson’s
n m modulus E,
°C MPa ratio ν
GPa
0 610 0.25 0.22 200 0.33
200 523 0.25 0.22 180 0.33
400 435 0.25 0.22 150 0.33
600 348 0.25 0.22 130 0.33
800 260 0.35 0.22 78 0.33
1 000 221 0.35 0.22 15 0.33
1 200 109 0.35 0.22 5 0.33
1 400 4 0.1 0.22 5 0.33
Fig. 1. Computational model: (a) The rectangular casting geome-
1 500 0.1 0.1 0.22 – 0.33
try, (b) Liquid Core Reduction Section.

© 2016 ISIJ 1618

ISIJ International, Vol. 56 (2016), No. 9

and the distinctive computational domains and sub-domains 3.2. Thermo-physical Properties and Boundary Condi-
for the SteelSim modeling as described before. The LCR tions
section below the mould includes 2 sets of guiding rolls The material considered for the simulations corresponds
(foot rolls), and 6 sets of rolls that are a part of the LCR to a low carbon steel having a composition of 0.045C,
section, as shown in Fig. 1(b). The rolls at the LCR section 0.2Mn (wt%). The corresponding thermo-physical proper-
are set-up to have a strand thickness reduction of 10.9 mm ties such as density, specic heat capacity, thermal conduc-
at the exit of the roll pair no. 8. The effect roll of alignment tivity, kinematic viscosity etc. are shown in Table 3. The
on strand deformation was studied by considering three uid ow is assumed as free up to a fraction of solid of 0.3
different roll congurations: (a) symmetrical alignment (with a xed linear increase in viscosity from the liquidus),
of rolls with LCR (having symmetrical closure of rolls), and from a fraction of solid of 0.3 to 1.0, a solidication
(b) asymmetrical alignment of rolls with LCR (having a source term is applied which accounts for the friction
single-sided closure of rolls), and (c) symmetrical align- against the solid network. The heat transfer at the copper
ment without LCR (fully vertical arrangement of rolls at mould and at the LCR section are set-up according to the
both sides), as shown in Fig. 2. For the asymmetrical case, data from the Tata Steel, IJmuiden thin slab caster, consider-
the row of rolls closing in the LCR (having the inwards roll ing both the actual primary and secondary cooling for the
displacement) is located at the loose side of the LCR, while given steel at the specied casting conditions. The heat ux
the roll conguration at the xed side remains fully vertical.
A set-up without LCR is used at the start of casting to allow
passing of a dummy bar and avoid excessive forces during Table 3. The thermo-physical properties of the low carbon steel.
the start-up. The corresponding casting machine geometry Specic heat Therma l Kinematic
and casting parameters are shown in Table 2. Temperature, Density,
capacity, conductivity, viscosity,
°C kg·m–3
J·kg–1·K–1 W·m –1·K–1 m 2·s–1
25 7 863 446 74.7 –
689 7 639 903 35.7 –
723 7 648 886 34.1 –
766 7 647 882 32.2 –
853 7 661 600 28.3 –
1 000 7 587 623 29.6 –
1 450 7 317 729 33.6 –
1 512 7 287 738 34.2 –
Fig. 2. The congurations in roll alignment: (a) symmetrical 1 531 7 132 785 34.8 1.60E-05
alignment of rolls with LCR, (b) asymmetrical alignment
of rolls with LCR, and (c) symmetrical alignment with no 1 533 7 030 817 35 8.03E-07
LCR. 2 230 6 449 795 35 3.27E-07
Thermal expansion coefcient, K–1 1.2 × 10 –5
Table 2. The casting machine geometry and casting parameters.
Liquidus temperature, °C 1 533
Mould cross section dimension thickness, m × width, m 0.09 × 1.25
Solidus temperature , °C 1 461
Mould length, m 1.1
Latent heat of fusion, kJ·kg–1 244
Mould wall thickness, m 0.025
Distance from meniscus to the top of mould, m 0.1
Strand width, m 1.25
Strand thickness, m 0.09
Roll diameter, m 0.13
Distance between mould and roll pair no. 1, m 0.12
Distance between roll pair no. 1 and 2, m 0.155
Distance between roll pair no. 2 and 3, m 0.155
Distance between roll pair no. 3 and 4, m 0.155
Distance between roll pair no. 4 and 5, m 0.155
Distance between roll pair no. 5 and 6, m 0.16
Distance between roll pair no. 6 and 7, m 0.16
Distance between roll pair no. 7 and 8, m 0.16
Casting speed, m·min–1 5
Pouring temperature, °C 1 540
Cooling water temperature, °C 50
Fig. 3. Cooling zones at the rolls section.

1619 © 2016 ISIJ

ISIJ International, Vol. 56 (2016), No. 9

set-up at the rolls section follows the description of the 5
cooling zones as shown in Fig. 3. During the simulation, the
meniscus level is xed in space i.e. free surface modelling
is not considered in the current model. The model assumes
full contact of the strand surface with the mould walls, thus
the inuence of air gap formation on heat transfer is cal-
culated in the model but already included in the total heat
ux set-up database. From the bottom of the mould down
to roll pair no. 8, free surface mechanical boundary condi-
tions are applied where the strand is not in contact with the
rolls, thus enabling the prediction of the strand deformation.
Moreover, at the LCR section the nite element grid adjusts
according to the amount of deformation, i.e. having nodal
displacement calculated during the simulation. The model
is arbitrarily adjusted below the domain of interest by hav-
ing a large increase of stiffness and cooling after roll pair
no. 8 where the strand continues to be pulled downwards.
This was done in order to have a stable numerical calcula-
tion by avoiding an excessive bulging deformation due to
the metallostatic pressure, and to simplify the geometry by
assuming a fully vertical cast strand. Also, the caster start-up
procedure was simplied and accelerated. Given the current
simplications in the model, it was found that a steady state
can be achieved at a time of 60 s. The results presented in
the following parts are down to roll pair no. 7, i.e. down
to 2.0 m from the meniscus. It is considered that the above
restrictions and articial boundary conditions, below roll
pair no. 8, have no inuence on the steady-state results from
roll pair no. 7 upwards.
the three roll congurations show little differences on the
temperature distribution at the wide face.
For all three cases, it is found that strand solidication
starts at about 30 mm below the meniscus. From this point
downwards the solid skin develops continuously. The solid
skin thickness at the mould exit is about 10 mm. Figure 5
exhibits the local surface temperature proles at the centre
of the narrow face (45 mm from the wide face surface of the
strand) from the meniscus down to 2.0 m. It can be seen in
Fig. 5 that the surface temperature tends to decrease inside
the mould and then increases after leaving the mould due to
the reduced cooling intensity at the secondary cooling zone.
It can also be noticed that there are no obvious differences in
temperature distribution between the three roll alignments.
Also, it was found that there are no signicant differences,
between the three roll alignments, on the development of
the solidication region of the strand (demonstrated by the
inner solid fraction development) (see Fig. 6).
4.2. Stress-strain Distribution
Figure 7 shows the mean stress distribution at the surface

4. Results and Discussion

4.1. HeatTransferandSolidication
Figure 4 shows the temperature prole of the strands
for the three roll congurations when the continuous cast-
ing time is ~60 s, i.e. at the steady state. The images show
the temperature contours at the wide face, loose side (the
rolls are hidden at this face in order to reveal the results). It
can be observed that the temperature of the strand surface
between the adjacent rolls is lower due to the simulated high Fig. 5. The local surface temperature proles at the centre of the
narrow face from the meniscus down to 2 m in length for
cooling rate provided by the water sprays. It was found that
three roll alignments.

Fig. 4. Temperature prole of the strands for the three roll align- Fig. 6. The inner solid fraction prole of the strand from roll pair
ments: (a) symmetrical alignment of rolls with LCR, (b) no. 1 to roll pair no. 6 for three different roll alignments:
asymmetrical alignment of rolls with LCR, and (c) sym- (a) symmetrical case with LCR, (b) asymmetrical case
metrical alignment with no LCR. with LCR, and (c) symmetrical case with No-LCR.

© 2016 ISIJ 1620

Citations (4) References (29)

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solidified shell; bulging of product between supporting rolls in the case of (CRC). Thermal contraction behaviors during solidification were measured
steel CC; size of final product, butt-curl defect in direct chill casting of as well in a T-shaped setup. The results showed that alloys with HTS from
aluminium. The numerical simulation package THERCAST has been high to low were AA7055, AA7085, AA7050 and AA7022. Zn content in 7×××
developed with the objective of ... [Show full abstract] aluminum alloys seemed to play a major ... [Show full abstract]

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Article

The Position Study of Heavy Reduction Process for

Improving Centerline Segregation or Porosity With...
April 2014 · Steel Research International

Xinkai Zhao · Jiongming Zhang · Shaowu Lei · Yuanning Wang

Limited by reduction radio, heavy plates manufactured from slabs are

always subjected to deterioration of soundness and mechanical properties.
For overcoming these defects, in the current works, a new approach, named
heavy reduction process to improve segregation and porosity, was
presented. The aim this study was to fix the dividing position of improving
centerline segregation or porosity. Based ... [Show full abstract]

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Last Updated: 24 Nov 2022

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