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<p>To accurately characterize multi-interface heat transfer in the continuous casting mold, a reliable representation of slab moving is essential. In this study, a three-dimensional thermo-mechanical coupled model with multi-interface heat transfer is developed for continuous casting. Two numerical approaches for modeling slab withdrawal, namely the mass flow rate method (MFRM) and the element birth-death method (EBDM), are systematically implemented and compared. The model incorporates mold heat transfer, slab thermo-mechanical deformation, and the dynamic evolution of mold flux and interfacial air gaps. The predicted solidified shell thickness is validated against measurements from breakout shell samples, showing good agreement with industrial data. The results reveal that both methods can capture the general characteristics of heat transfer and solidification behavior. However, EBDM exhibits strong dependence on mesh resolution and tends to overestimate shell thickness under coarse mesh conditions due to its layer-wise activation mechanism. In contrast, MFRM provides smoother temperature distributions, improved numerical stability, and significantly reduced mesh sensitivity by describing slab motion through continuous mass flux. Furthermore, differences in interfacial structure evolution are observed, where EBDM predicts earlier air gap formation and larger gap thickness, resulting in lower heat flux and temperature levels. Overall, MFRM demonstrates superior performance in terms of computational efficiency, solution continuity, and suitability for multi-physics coupling. This study provides a robust framework for high-fidelity simulation of continuous casting processes and offers guidance for selecting appropriate numerical methods in multi-interface thermo-mechanical modeling.</p>

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Mass Flow Rate and Element Birth-Death Methods for Simulating Slab Moving in Multi-interface Heat Transfer Issue in Continuous Casting: A Comparative Study

  • 期刊论文

  • 发表日期：

    2026年7月10日

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  • Hang Zhang,
  • Weiling Wang,
  • Yelian Zhou,
  • Zhongkuai Jiang,
  • Zhaozhen Cai,
  • Miaoyong Zhu

摘要

To accurately characterize multi-interface heat transfer in the continuous casting mold, a reliable representation of slab moving is essential. In this study, a three-dimensional thermo-mechanical coupled model with multi-interface heat transfer is developed for continuous casting. Two numerical approaches for modeling slab withdrawal, namely the mass flow rate method (MFRM) and the element birth-death method (EBDM), are systematically implemented and compared. The model incorporates mold heat transfer, slab thermo-mechanical deformation, and the dynamic evolution of mold flux and interfacial air gaps. The predicted solidified shell thickness is validated against measurements from breakout shell samples, showing good agreement with industrial data. The results reveal that both methods can capture the general characteristics of heat transfer and solidification behavior. However, EBDM exhibits strong dependence on mesh resolution and tends to overestimate shell thickness under coarse mesh conditions due to its layer-wise activation mechanism. In contrast, MFRM provides smoother temperature distributions, improved numerical stability, and significantly reduced mesh sensitivity by describing slab motion through continuous mass flux. Furthermore, differences in interfacial structure evolution are observed, where EBDM predicts earlier air gap formation and larger gap thickness, resulting in lower heat flux and temperature levels. Overall, MFRM demonstrates superior performance in terms of computational efficiency, solution continuity, and suitability for multi-physics coupling. This study provides a robust framework for high-fidelity simulation of continuous casting processes and offers guidance for selecting appropriate numerical methods in multi-interface thermo-mechanical modeling.