Continuous Casting Machine Tool Optimization: A Step Closer to the Digital Twin

If you missed this special session that brought together our in-house experts Dr. François Frascati (Product Manager), Dr. Gregory Puaux (THERCAST^® Developer), and Arianna Gotti (Casting Expert) to share insights into the digital transformation of continuous casting in the steel industry, this article is made for you! 

Why Continuous Casting Needs Digital Innovation

Continuous casting is a core process in the steelmaking (other materials are also available in the solution: aluminium basis, copper basis, titanium basis...)  industry—complex, high-stakes, and difficult to control in real time. Optimizing this process means being able to accurately simulate multiple physical phenomena, from thermal and hydraulic behavior to mechanical deformation and electromagnetic influences. 

At Transvalor, we are helping companies master this complexity using THERCAST^®, our multiphysics simulation software, major competitive advantage compared to other solutions on the market. In this webinar, we demonstrated how our solution supports continuous casting machine optimization, aligning with the broader vision of implementing digital twins in manufacturing. 

Building a Virtual Casting Machine

To simulate the behavior of a continuous casting line, we first need to digitize the equipment itself: 

1. Data Collection: Drawings, CAD models (latest and as-built versions), and relevant technical specs. 

1. Digital Setup: Users can build a virtual machine using a structured data sheet (provided by Transvalor) or directly within the CC Machine Tool interface. 

1. Component Integration: Mold definitions, steering systems, and other critical parts are integrated into the model. 

1. Solver Selection: Based on the desired results (thermal, mechanical, electromagnetic, etc.), the appropriate solver is applied. 

This structured approach brings us one step closer to a true digital twin of the continuous casting process—enhancing predictive capabilities and process control. This approach allows us also to digitalize a wide range of casters from very old technology to very new directly depending on the data we can obtain (drawings, CAD...).  

THERCAST®: A Multiphysics Powerhouse

The latest release of THERCAST^® NxT 3.0 introduces even more power and flexibility for industrial users. The software is capable of handling various casting processes, including: 

• Continuous casting : Primary and Secondary cooling, Horizontal Continuous Casting, Direct Chill Casting, Tundish 

• Ingot casting : Bottom and Top pourring, Tundish 

• Foundry: High pressure die casting (HPDC), low pressure die casting (LPDC), gravity casting, centrifugal casting, investment casting, and lost foam casting 

THERCAST^® supports simulation with or without Electromagnetic Stirring (EMS) and integrates thermal, hydraulic, and mechanical solvers. Whether you're analyzing filling, cooling, or solidification, THERCAST^® adapts to your industrial needs.

THERCAST^® supports large panel of materials, from different steels grades to aluminium, titanium and more. Macrosegregation and micro-structure prediction can also be used to manage the final quality and properties of the raw materials.  

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