Real-Time Force Prediction Model of Blooms in the Reduction

During continuous casting, accurate real-time prediction of strand solidification ensures the effective implementation of reduction. Due to the influences of the continuous casting production environment, equipment, and other factors, the calculations from a thermal tracking model deviate; these deviations are difficult to find and correct in real time, affecting the effective implementation of the casting process. In this paper, the online calculation processes are explored for the stress–strain and force–reduction relationships during reduction. Based on the calculation results of the finite element model for the cross-sectional strain distribution during reduction, the influences of certain parameters, such as reduction, dimension, steel, and reduction position, on the strain distribution of the bloom cross section during reduction are analyzed. Reduction amount is the main factor affecting the strain distribution; within a certain range, the element strain is linear with the reduction. Based on this finding, a real-time bloom force prediction model is proposed in this paper. The model combines the strain distribution trend of the finite element model of thermal–mechanical coupling and calculates the strain and strain rate of each element of the cross section according to the actual reduction process. By combining the real-time temperature results of the thermal tracking model with the constitutive characteristics of the steel determined in the experiment, the stress–strain and force–reduction relationships during continuous casting are accurately predicted. According to a comparison with the actual force of the on-site reduction process, the error is generally less than 5 pct; however, the error differs for equipment problems. The calculation results show that the ambient temperature (5 °C and 10 °C) also affects the actual compaction force during the reduction process. The force deviation at different ambient temperatures is about 5 to 10 pct. Through a comparison of bloom temperature and force data, the on-site thermal tracking model can be verified in real time, and the conditions of the reduction equipment can be preliminarily diagnosed.