Materials Today: Proceedings xxx (xxxx) xxx
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Improvement of continuous billet casting machines V.I. Odinokov a, E.A. Dmitriev b, A.I. Evstigneev a,b,⇑ a b
Lenina 27, Komsomolsk-na-Amure 681013, Russia Metallurgov 1, Komsomolsk-na-Amure 681005, Russia
a r t i c l e
i n f o
Article history: Received 7 May 2019 Received in revised form 15 July 2019 Accepted 24 July 2019 Available online xxxx Keywords: Machines Designs Billet Casting Deformation
a b s t r a c t The paper describes disadvantages of known designs of machines and their components, represents new more advanced designs of continuous billet casting machines improving their quality, operational reliability and ease of operation. Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Modern Trends in Manufacturing Technologies and Equipment 2019.
1. Introduction Severization of the requirements to engineering productsmake it necessary to improve the quality of billets, and production process stability, that is largely dependent on processing capability and specifications of the equipment used. Method of continuous billet casting applying the Casting and Forging Module (CFM) developed by Professor V. I. Odinokov differs essentially from the known production processes and continuous billet and steel product casting machines. The advantage of the continuous billet casting process using the CFM is that outer surface and internal structure of the billet made of molten metal poured into the machine are formed under external forces induced by moving faces of the mold. Factors which, among others, considerably impact the process stability are the design and process variables of continuous billet casting including the design and geometry of the mold, temperature and the level of molten metal poured into the mold, and modes of molten metal pouring into the mold. However, available publications do not address combined effect of these factors on the continuous billet casting process. The method of optimum process variable selection is not described either. These are dependent on the machines used and peculiarities of their design.
⇑ Corresponding author. E-mail address:
[email protected] (A.I. Evstigneev).
Thus, a machine [1] is known comprising a tundish with a submerged entry nozzle and a vertical mold with a pair of walls with inclined upper and lower working faces, each fixed on individual eccentric parallel horizontal shaft, and a pair of working walls, each fixed on the lower drive eccentric shaft, that reciprocate toward the first pair of walls. The disadvantage of this machine is the need in ensuring the required rigidity when casting the slab of considerably large width (more than two meters). The lower eccentric shaft diameter shall be increased to achieve the required shaft rigidity necessary to cast a slab varying in thickness across the width. This inevitably leads to an increase in the quantity of metal per the entire machine and consequently to an increase in its cost. 2. Results To reduce the quantity of metal, a new design of the machine [2] is proposed comprising a tundish with a submerged entry nozzle and a vertical mold with a pair of working walls with inclined upper and gaging lower working faces and a second pair of reciprocating vertical working walls. The supports to which the side walls are fixed are provided with the grooves in the horizontal plane of the lower eccentric shaft where expanding rods are installed thrusting at one end into the bearing on the eccentric shaft and at the other end into the side walls of the frame. Fig. 1 shows the assemblies of the machine (sections A-A and B-B).
https://doi.org/10.1016/j.matpr.2019.07.678 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Modern Trends in Manufacturing Technologies and Equipment 2019.
Please cite this article as: V. I. Odinokov, E. A. Dmitriev and A. I. Evstigneev, Improvement of continuous billet casting machines, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.07.678
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V.I. Odinokov et al. / Materials Today: Proceedings xxx (xxxx) xxx
Fig. 1. Continuous Slab Casting Machine.
The machine comprises a vertical mold with a pair of walls 1 with inclined faces 2 and gaging faces 3 and a pair of working walls 4. Working walls of the vertical mold are driven by the splined shaft 5 via the splined eccentric bushings 6. The linear bushings 7 are installed on the lower shaft serving as support for one end of the expanding rods 8 the other end of which thrusts into the frame walls 9. Openings 10 are provided in the lower part of the support for rod installation. Machine operation: molten metal is poured from the tundish into the composite mold with moving walls driven by the shaft 5 via the eccentric bushings 6 where the metal is cooled due to heat removal through the mold walls, then formed and pushed downwards as a slab of the pre-defined cross-section. The solidified slab is finally formed in the lower section of the mold. The deformation forces are taken up by the drive eccentric shaft. Shaft bending in the horizontal plane is prevented both by the shaft itself and by the expanding rods 8, thrusting at one end into the shaft 5 via the linear bushing 7 and at the other end into the side wall 9 of the frame. While preventing the shaft bending, the expanding rods also destress bearings in the frame in which the eccentric shaft rotates. Another disadvantage of the continuous billet casting machine [1] is as follows. When producing billets of a large cross-section, the rate of heat removal from the solidifying metal through the mold structure shall be increased and thus the mold height shall be increased too. Hence the diameter of the eccentric shafts shall be increased to achieve the design structural rigidity which leads to increase in the quantity of metal per the entire machine and consequently to an increase in its cost. To reduce total equipment weight, a machine [3] is proposed comprising a tundish with a submerged entry nozzle and a vertical mold. The mold comprises a pair of working walls with inclined upper and vertical lower working faces and a second pair of reciprocating working walls. Each wall is fixed to the support rotating on three eccentric shafts, herewith the structural rigidity is increased and quantity of metal is reduced. Fig. 2 shows machine appearance (vertical center plane section). The machine comprises a tundish 1 with a submerged entry nozzle 2 and a vertical mold with a pair of walls 3 with inclined faces 4 and gaging faces 5 and a pair of working walls 6 with vertical faces 7. Through-holes 8, 9, 10 are provided in the working walls 3 for the drive shafts 11, 12, 13. Machine operation: molten metal is poured from the tundish 1 via the submerged entry nozzle 2 into the composite mold with moving walls driven by the drive eccentric shafts 11, 12, 13 where the metal is cooled due to heat removal through the mold walls, then formed and pushed downwards as a billet of the pre-
Fig. 2. Continuous Large Cross-Section Billet Casting Machine.
defined cross-section. There are three zones in the mold: molten metal zone, molten metal and shell zone, and solid metal zone. The process shall ensure that the solid metal zone starts in the horizontal plane of the center eccentric shaft. Another disadvantage of the known machine [1] is that working walls are fabricated of heat-resistant steel reducing the efficiency of heat removal from the solidifying metal through the mold. To increase the reliability and efficiency of the machine, new design of the machine [4] is proposed comprising a tundish, a vertical mold formed by a pair of working walls with inclined upper and vertical lower faces rotating on two eccentric shafts and a second pair of reciprocating vertical working walls. Each wall is fitted with water-cooled inserts improving the heat exchange, not deteriorating the strength of the machine but increasing the machine performance. Figs. 3 and 4 show the machine appearance and section A-A respectively. The machine comprises a tundish 1 with a submerged entry nozzle 2 and a vertical mold with a pair of walls 3 with inclined and vertical faces 4 fixed to the eccentric shafts and a pair of vertical walls 5. Walls 3 and 5 are fitted with water-cooled copper inserts 6 and water-cooled heat-resistant steel inserts 7. Machine operation: molten metal is poured from the tundish 1 via the submerged entry nozzle 2 into the composite mold with moving walls 3, 5 driven by the eccentric shafts 4. In zone I, where the temperature is the highest, the heat is removed through the water-cooled copper inserts 6. In zones II
Please cite this article as: V. I. Odinokov, E. A. Dmitriev and A. I. Evstigneev, Improvement of continuous billet casting machines, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.07.678
V.I. Odinokov et al. / Materials Today: Proceedings xxx (xxxx) xxx
Fig. 3. Continuous Billet Casting Machine Appearance.
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and closed-bottom submerged entry nozzle with two outlet ports located above and below the horizontal centerline. Axes of the outlet ports pass through the nozzle center. The drawback of this known machine is that use of the above described nozzle does not ensure required homogenization of the molten metal across the horizontal plane of the mold resulting in different structure of the solidifying metal in a horizontal section and making it difficult to produce quality steel products in the process of rolling. Moreover such a design of the submerged entry nozzle necessitates frequent nozzle replacement (outlet ports are washed out potentially leading to separation of the nozzle bottom). Some publications describe the use of a distributor installed on the brackets under metal exit from the submerged straightthrough nozzle. The distributor is used for rounds casting [[5], pages 381–382]. The distributor is a receiver used to distribute the molten metal across the round mold walls. The distributor is filled with the molten metal to a pre-defined level which shall be higher than the metal level in the mold. Molten metal is poured through the center outlet port in the distributor into the mold as a single jet only into the center of molten metal contained in the mold, whereby metal is unevenly supplied into the mold around the perimeter in the horizontal section and thus the metal is homogenized only partially. The machine designed by the inventors differs from the known machine in that the deflector is installed on the brackets under the metal exit from the submerged straight-through nozzle. The deflector shape is identical to the horizontal section of the billet.
Fig. 4. Continuous Billet Casting Machine Section A-A.
and III, where the metal is solidified and the forces acting on the walls 3, 5 are high, the heat is removed from the solid metal through the heat-resistant steel inserts 7. The process most widely used in the steel industry involves pouring of molten metal into the continuous steel/billet casting machine via the tundish, mold with walls of various geometry
Fig. 5. Metal Pouring in Continuous Steel Casting Machine (1) tundish; (2) submerged nozzle; (3) deflector; (4) mold; (5) bracket.
Please cite this article as: V. I. Odinokov, E. A. Dmitriev and A. I. Evstigneev, Improvement of continuous billet casting machines, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.07.678
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As molten metal is poured through the submerged straightthrough nozzle onto the deflector, the jet will be evenly distributed in all directions and thus will evenly flow over the entire inner surface of the round or square mold in the horizontal section. The deflector can be of round, square or rectangular shape corresponding to the billet cross-section. This contributes to achieving the homogeneous structure of the solidifying metal in the horizontal plane when casting the rounds or other shapes. Molds with the submerged straight-through nozzle and deflector are simpler and cheaper to manufacture than closed-bottom submerged nozzles with outlet ports. Fig. 5 shows the machine appearance. The machine comprises a tundish 1 with a submerged straight-through nozzle 2 and a deflector 3 fixed on the mold 4 using the brackets 5. Machine operation: molten metal if poured from the tundish 1 through the submerged straight-through nozzle 2 onto the deflector 3 of the pre-defined cross-section and is distributed in the horizontal plane toward the inner walls of the mold 4. Deflector 3 is held in position using brackets 5 to withstand molten metal pressure. This design allows uniform distribution of the metal around the mold perimeter in the horizontal plane thus contributing to achieving the homogeneous structure of the solidifying metal in the horizontal plane when casting round, square or rectangular billets.
3. Conclusions Improved designs of the machines and their components implemented in the casting and forging plants currently in operation were developed to improve the quality of continuous cast billets, diversify billet dimensions, reduce the quantity of metal per the machine and increase operational reliability. A machine allowing production of the continuous cast thin slabs of considerable width and continuous cast armor slabs of large thickness is described. References [1] RF patent No. 2041011, MGR B22L 11/04, RU 09/08/1995. Continuous Billet Casting Machine / V. I. Odinokov. Patent Holder: Institute of Metallurgy and Mechanical Engineering under the Far-Eastern Branch of RAS. - No. 92007791/ 02; applied for on 24.11.1992; published on 09.08.1995. [2] RF patent No. 2645627, MGR B22L 11/04. Continuous Slab Casting Machine / V. I. Odinokov., M. Yu. Tuev, E. A. Dmitriev, A. I. Evstigneev. Patent Holder: Komsomolsk-na-Amure State University. - No. 2017113474; applied for on 18.04.2017; published on 26.02.2018. Bulletin No. 6. [3] RF patent No. 2647721, MGR B22L 11/04. Continuous Large Cross-Section Billet Casting Machine / V. I. Odinokov., M. Yu. Tuev, E. A. Dmitriev, A. I. Evstigneev. Patent Holder: Komsomolsk-na-Amure State University. - No. 2017114442; applied for on 25.04.2017; published on 19.03.2018. Bulletin No. 8. [4] RF patent No. 2678719, MGR B22L 11/04. Continuous Billet Casting Machine / V. I. Odinokov., E. A. Dmitriev, A. I. Evstigneev. Patent Holder: Komsomolsk-naAmure State University. - No. 2018112511; applied for on 06.04.2018; published on 31.01.2019. Bulletin No. 4. [5] E. Herrmann, Continuous Casting, Gosnauchtechizdat, Moscow, 1961.
Please cite this article as: V. I. Odinokov, E. A. Dmitriev and A. I. Evstigneev, Improvement of continuous billet casting machines, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.07.678