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SIMULATION AND ONLINE MEASUREMENT OF NARROW FACE MOLD DISTORTION IN THIN-SLAB CASTING

The thermal distortion of the narrow face mold plates in a funnel-mold caster is explored with numerical simulation and online measurements. A three-dimensional finite-element model of the mold and waterbox with full geometric detail is used to explore the evolution of temperature and distortion of the mold during startup. The thermal boundary conditions are calculated with the continuous-casting heat transfer model CON1D, which was calibrated with plant measurements. The model predictions agree with measurements from inclinometers installed on the top and bottom of a mold plate to within about 1 arc-minute (better than 5%). Before a width change, the clamping forces and friction between the narrow and wide face mold plates resist the tendency for the narrow face to move and bend. After unclamping for a width change, the narrow face distorts into a parabolic shape according to the stiffness of the restraining bolts and waterbox. The applied taper in the plant must account for these two different narrow face shapes to match the shrinkage of the solidifying steel shell and to ensure good product quality. For the mold under consideration, the distortion of the narrow face increases the effective taper and leads to increased mold wear.