With current capabilities of software solutions the classical use of simulation evolves to process optimization. Integrated statistical tools such as virtual Design of Experiments allow performing systematic virtual experimentation of a process window. This enables the expert to identify significant process parameters and to investigate the effect of parameter changes without expensive trials in the shop floor. Based on this knowledge, optimized casting processes can be designed, that are both, cost-effective and robust with respect to process variations.

State-of-art simulation tools provide quantitative insights in flow, solidification and stress formation for continuous casting processes. This includes the entire process, from the tundish and the flow into the mold to the solidifying strand, which is withdrawn through various cooling zones. Process simulation provides important information about quality and productivity to evaluate process alternatives.

Firstly, the presentation will discuss the modeling of electromagnetic stirring (EMS) and its impact on the flow behavior. Additionally a second focus will be the evaluation of new criteria to avoid the formation of cracks. With the help of a stress calculation results for cold crack formation and also hot tearing are available. The stress simulation is also been used to described the gap formation in mold and the corresponding change of heat transfer conditions.

The results will be presented for industrial billet and bloom casters. With the availability of the integrated process know in a digital twin optimal operating points for quality improvements and productivity increases can be investigated. The final objective is to derive a comprehensive model for online monitoring and optimized dynamic online control of the cooling and solidification process.