To comprehensively investigate the formation mechanism and alleviation technology of internal cracks in steel 100Cr6 during the soft reduction process, a three-dimensional mechanical model has been developed to obtain equivalent strain of as-cast bloom under different reduction amount and reduction position. The specific relationship between area of cracking zone, centre solid fraction and maximum equivalent strain of cracking zone has been researched under a number of withdrawal units. In the present work, a novel soft reduction technology for eliminating internal cracks, center shrinkage cavities and center segregation of as-cast bloom has been designed, which aims to provide theoretical basis for improving the internal quality of steel 100Cr6. According to the results of optimum designed experiments, the internal cracks were effectively alleviated and center shrinkage cavities were nearly eliminated. In addition, the center segregation generated by the optimum designed experiments of steel 100Cr6 was remarkably improved in comparison with that induced by the conventional soft reduction process.
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