Thermo-mechanical finite element simulation and fatigue life assessment of a copper mould for continuous casting of steel

This work describes the thermo-mechanical analysis of a copper mould for continuous steel casting. During the process, the molten steel passes through a water cooled mould. The inner part of the component is subjected to a huge thermal flux. Consequently large temperature gradients occur across the component, especially in the region near to the meniscus, and cause elastic and plastic strains. The aim of this work is to set up an industrially oriented approach to assess the fatigue life of the copper mould. To achieve the goal, a three-dimensional finite element model is analyzed in dependence of four different material models (linear kinematic hardening, combined, stabilized and accelerated material model). The main question is which material model is more suitable to be used. Material coefficients for all applied material and fatigue life models are estimated from experimental, isothermal low cycle fatigue data. The fatigue life is also assessed depending on different material models. The results obtained with the FEM analysis are examined and compared.