The study focuses on the four-strand tundish as the research object, aiming at the phenomenon of fewer strand casting (stable blockage) and sudden blockage of the tundish in industrial production. Numerical simulation methods are employed to compare the velocity vectors, flow fields, residence time distribution (RTD) curves, and outflow percentage curves under stable blockage and sudden blockage of the tundishes with a double-weir structure, U-shaped weir structure, and U-shaped weir structure with holes in the front. The results indicate that, after sudden blockage of the tundish strands, the flow field transitions from an unstable four-strand flow field to a stable three-strand flow field. Both the double-weir tundish and the U-shaped weir tundish reach a stable state after 200 s, while the U-shaped weir tundish with holes in the front reaches stability after 150 s. Additionally, compared to other structures, the tundish strands of the U-shaped weir with holes in the front are less affected by blockage, showing better consistency among strands and better adaptability under non-standard casting conditions.

In continuous casting, fewer strand operations are sometimes required to match production schedules. However, the study of flow behavior and temperature distribution under fewer strand casting conditions remains insufficiently systematic, especially with regard to the grade casting process, which has not yet been explored. This study presents an innovative investigation of the grade transition process in a symmetrical 12-strand tundish under fewer strand casting conditions. Seven operational cases were analyzed: standard casting (the normal symmetric Case 0), individual closure of strands 1–6 (the asymmetric Cases 1–6), and simultaneous closure of strands 1–2 (the asymmetric Case 7). Notably, strand closures in Cases 5 and 6 significantly impair flow characteristics in their respective strands. The impact area temperature reaches approximately 1844 K (new heat) after 30 min of continuous casting. However, Case 6 exhibits persistent low-temperature regions near strands 5 and 6. The average transition billet lengths for Cases 0 to 7 are 72.41 m, 70.16 m, 70.30 m, 71.68 m, 72.95 m, 72.12 m, 76.35 m, and 65.45 m, respectively. Based on a comprehensive evaluation of flow dynamics, temperature uniformity, and transition billet length, Case 1 emerges as the most favorable single-strand closure strategy. Operational recommendations suggest avoiding strand closure patterns implemented in Cases 5 and 6 during reduced strand casting operations.