Continuous casting of steel in an industrial billet caster is modeled numerically including multiphase turbulent flow, mold electromagnetic stirring (M-EMS), heat transfer, and solidification. Two different steel grades (case-hardening and micro-alloyed steel) and casting powders are considered in the study to evaluate the castability and powder performance. Existing models to estimate thermophysical properties of casting powders are reviewed and compared to measurement data. Complex mold taper design is considered by constructing a digital twin and applying a corresponding velocity for the solidified shell in 3D. Slag infiltration is simulated from the beginning of casting to steady operation as a function of shell solidification and resulting heat transfer between liquid steel and oscillating mold wall. Additionally, the model predicts air gap size, excessive taper, and mold friction through a quasi-thermomechanical analysis. This includes a new approach to estimate mold friction based on Lubrication Index (LI) and Contact Index (CI) concepts. The resulting shell thickness, cooling water temperature, nail-dipping measurement, and mold friction are compared to plant data and literature for validation. This novel modeling approach can address phenomena difficult to analyze on real casters such as slag entrainment and infiltration, corresponding thermal response, and contact conditions between shell, slag, and mold.

在工业钢坯连铸机中对钢的连续铸造进行了数值模拟，包括多相湍流、结晶器电磁搅拌 (M-EMS)、传热和凝固。研究中考虑了两种不同的钢种（表面硬化钢和微合金钢）和铸造粉末，以评估铸造性和粉末性能。评估铸造粉末热物理性能的现有模型进行了审查，并与测量数据进行了比较。通过构建数字孪生并在 3D 中为凝固壳应用相应的速度来考虑复杂的模具锥度设计。炉渣渗透从铸造开始到稳定运行进行模拟，作为壳凝固和由此产生的钢水和振荡模具壁之间的热传递的函数。此外，该模型通过准热机械分析预测气隙尺寸、过度锥度和模具摩擦。这包括一种基于润滑指数 (LI) 和接触指数 (CI) 概念来估算模具摩擦的新方法。将得到的壳厚度、冷却水温度、浸钉测量和模具摩擦与工厂数据和文献进行比较以进行验证。这种新颖的建模方法可以解决在真实连铸机上难以分析的现象，例如夹渣和渗入、相应的热响应以及壳、渣和模具之间的接触条件。将冷却水温度、浸钉测量和模具摩擦与工厂数据和文献进行比较以进行验证。这种新颖的建模方法可以解决在真实连铸机上难以分析的现象，例如夹渣和渗入、相应的热响应以及壳、渣和模具之间的接触条件。将冷却水温度、浸钉测量和模具摩擦与工厂数据和文献进行比较以进行验证。这种新颖的建模方法可以解决在真实连铸机上难以分析的现象，例如夹渣和渗入、相应的热响应以及壳、渣和模具之间的接触条件。