Modeling thermo-mechanical fatigue for rolling die under continuous casting process

In the continuous casting process, the rolling die is exposed to non-steady stress conditions that can initiate thermo-mechanical fatigue damage. Understanding the rolling die failure mechanism is essential in metal-forming industries. Thermo-mechanical fatigue damage mechanism (crack growth) is governed by highly localized stresses in the crack tip region. This paper presents analytical models to determine thermo-mechanical fatigue failure mechanism based on the elastoplastic fracture mechanics and continuum damage mechanics. The model includes new proposed analytical equations for low-cyclic fatigue crack propagation. To verify the analytical models, experimental data and finite element simulation are considered. Results show good agreement with experimental data and finite element simulation.