A 2.5D finite element model for bending and straightening in continuous casting of steel slabs

This paper presents a bi-dimensional slice model of the continuous casting process developed to focus on the risk of transverse cracking during bending and straightening of steel slabs. The model is based on the finite element method and it integrates both thermal and mechanical aspects: temperature evolution, solidification, stress and strain developments. Generalized plain strain conditions are applied in the casting direction, allowing taking account of the extraction force applied to the slab as well as strains in this direction. The model also includes an original solution to counteract the generally wrong modelling of slab bulging with such slice models. The model has been applied to an industrial case of slab casting. Some numerical results illustrate the accuracy of the model compared to results of other models, measurements and observations on the caster. Transverse cracks are predicted to be the most likely to occur at the edge on the upper face, at the end of straightening of the slab. This is due to the combination of low ductility of the material with tensile stress and elongation in the casting direction in the straightening zone. This conclusion has been confirmed by the examination of slabs that present transverse cracks. Copyright 2006 John Wiley & Sons, Ltd.