CN113426970B - Vertical semi-continuous production device and production process of large round billets with phi of 1000 mm-2000 mm - Google Patents
Vertical semi-continuous production device and production process of large round billets with phi of 1000 mm-2000 mm Download PDFInfo
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- CN113426970B CN113426970B CN202110652729.7A CN202110652729A CN113426970B CN 113426970 B CN113426970 B CN 113426970B CN 202110652729 A CN202110652729 A CN 202110652729A CN 113426970 B CN113426970 B CN 113426970B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/14—Plants for continuous casting
- B22D11/141—Plants for continuous casting for vertical casting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/12—Accessories for subsequent treating or working cast stock in situ
- B22D11/124—Accessories for subsequent treating or working cast stock in situ for cooling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/12—Accessories for subsequent treating or working cast stock in situ
- B22D11/128—Accessories for subsequent treating or working cast stock in situ for removing
- B22D11/1281—Vertical removing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
The invention discloses a vertical semi-continuous production device of a large round billet with the diameter of phi 1000 mm-phi 2000mm and a production process thereof, relates to the technical field of ferrous metallurgy casting, and particularly relates to a vertical semi-continuous manufacturing device of a large round billet with the diameter of phi 1000 mm-phi 2000mm and the length range of 5m-15m and a production method thereof. The invention discloses a pipeline type induction heating ladle base which is an auxiliary system of a pouring system; the pouring system, the cooling system and the casting blank lifting system are sequentially arranged from top to bottom; the split type electromagnetic stirring system and the casting blank temperature control system are arranged around the round blank as the casting blank quality control system; the ejection system, the casting blank conveying slideway and the casting blank slow cooling system are sequentially arranged on one side of the production device. The technical scheme of the invention solves the problems of low productivity in the prior art; the energy consumption is high; large occupied area and investment; is not suitable for customized production; the core quality is difficult to control, and the problems of macrosegregation, looseness, shrinkage cavity and the like are easy to occur; quality control is difficult to realize, and the like.
Description
Technical Field
The invention discloses a vertical semi-continuous production device of a large round billet with phi 1000 mm-phi 2000mm and a production process thereof, relates to the technical field of ferrous metallurgy casting, and particularly relates to a vertical semi-continuous manufacturing device of a large round billet with the diameter of phi 1000 mm-phi 2000mm and the length range of 5m-15m and a production method thereof.
Background
With the rapid development of nuclear power, wind power, hydropower and steel industries and the development trend of large-scale equipment, the market has more and more large demand on high-quality large castings, wherein the large shaft castings of phi 1000 mm-phi 2000mm, which are made of high-quality special steel, are products with more market demands, and are widely applied to the fields of large supporting rollers, fan shafts, rotors of nuclear power and hydroelectric generating sets, ship spindles, bearings and the like. Meanwhile, the downstream industry still urgently requires to reduce the manufacturing cost of the whole machine, so that the upstream industry is required to further optimize the production flow, reduce the consumption of materials and energy and shorten the processing period on the basis of ensuring the supply quality of the cast ingots.
The large round billet with the diameter of 1000mm to 2000mm is characterized by large single weight and section, long solidification time, most of materials are high alloy variety steel, high requirements on internal quality and purity, and multiple customized production modes with single batch and small batch. The casting quality of the large round billets is extremely difficult to control: first, extension of the solidification time can lead to serious segregation problems; secondly, a wide liquid-solid two-phase region of a liquid core can be caused by high alloy content, developed dendrites generated can influence the fluidity of molten steel, and the core part is easy to be defective; finally, the uneven shrinkage of the cooling is prone to cracking due to the large cross-sectional size of the cast slab.
At present, in order to produce the large-specification round shaft casting blank with high density, high cleanliness, high uniformity and low defect rate, an electroslag casting method [1], a die casting forging method [2], a continuous casting method [3] and a method of combining electroslag and continuous casting [4] are mostly adopted in practice. In addition to the die casting forging method, other techniques generally configure the electromagnetic stirrer to control the quality of the core, but the configuration and the use method of the electromagnetic stirrer are greatly different. At present, the patents which have been applied in China cover the methods, but the technical applicability and the economical efficiency are greatly different according to the difference between the size specification of the round billet and the target product. The concrete technical characteristics are as follows:
[1] CN101480715A electroslag casting device with additional electromagnetic stirring and method thereof
An electroslag casting device with additional electromagnetic stirring and a method thereof belong to the technical field of special steel electroslag metallurgy, and comprise a crystallizer, a crystallizer water jacket and an electromagnetic stirrer, wherein the outer wall of the crystallizer is sleeved with an annular magnet which is positioned at the middle upper part of the crystallizer, a coil is wound on an iron core of the annular magnet, the electromagnetic stirrer water jacket is arranged around the annular magnet, and the electromagnetic stirrer water jacket is communicated with the crystallizer water jacket; molten steel drops formed by the molten consumable electrode enter a slag layer, the molten steel drops fall in the slag layer in a spiral line mode under the action of an external rotating electromagnetic field and enter a steel ingot liquid pool, the steel ingot liquid pool continuously rises and also enters an effective magnetic field action area of an electromagnetic stirrer, and at the moment, the current in the molten steel and the rotating magnetic field act to generate electromagnetic force to drive the molten steel to rotate
[2] Forging process (die casting forging method) of large shaft parts such as CN102172766A nuclear power rotor and the like
The invention discloses a forging process of large shaft parts such as nuclear power rotors and the like, which can effectively solve the forging problem of ultra-large-specification high-grade rotors. The process specifically comprises the following steps: 1) Drawing out the steel ingot into a flat square by adopting a WHF method; 2) Carrying out vertical upsetting on the flat square; 3) Adopting a WHF method to draw the upset billet into a flat square again; 4) Carrying out four-side center compaction on the flat square;
[3] CN108436046A vertical continuous casting production equipment and method of an oversized round billet (continuous casting method):
the casting method adopts vertical continuous casting equipment and a method, and the main equipment comprises a steel ladle, a tundish, a crystallizer, a blank drawing system and a blank discharging system, wherein the blank discharging system comprises a casting blank discharging device, a casting blank combining device, a casting blank lifting device and an upper blank discharging roller way. The method is mainly suitable for producing various steel grades such as carbon steel, bonded steel and the like aiming at ultra-large section round billets with phi 600 mm-phi 1300mm, thereby realizing continuous production of large-section high-quality billets. The technological process is the same as that of traditional continuous casting process, and the difference is that the throwing system is provided with a flame cutting machine, so that the casting blank can be cut on line and conveyed out through the discharging system.
[4] Method and apparatus for producing longer ingots with larger cross-section in CN106029254A
[ METHOD OF COMBINING ELECTROSLAG AND CONTINUOUS CASTING ]
The technique is directed to the objective of producing round or polygonal, square or rectangular shaped ingots having a cross-sectional area in the range of more than 300mm in diameter or equivalent to other cross-sectional shapes in round ingots and a length of more than 5m. The cast ingot is cast in a short, water-cooled metal mold until the desired ingot length is reached, and the metal casting bath is subsequently heated by the electroslag method with the aid of self-consumable electrodes, or the heated tundish or heatable cover is subsequently heated, and the solidification structure is influenced by an electromagnetic stirrer during and after the end of casting until the end of solidification.
The current manufacturing technology of large round billets mainly has the following problems:
firstly, the electroslag casting technology is extremely slow in blank drawing, and extremely large electric energy is consumed in the process, so that the production efficiency is extremely low, and the energy consumption cost is extremely high;
secondly, for the die casting and free forging technology, a riser end and a water port end need to be cut off in the die casting process of the large steel ingot, the utilization rate of materials is low (50% -70%), and the cost and energy consumption of subsequent forging and processing of the technology are also high;
thirdly, as for the continuous casting technology, although the material cost and the continuous production are superior to the former two, the diameter of the cast round billet reaches the limit when the diameter reaches phi 1000mm, and the equipment occupies a large area and has high investment cost, so that the continuous casting technology is not suitable for a single-batch and small-batch product customization production mode;
fourthly, for the method combining electroslag with continuous casting, although the problems of riser feeding and temperature compensation can be well solved, the direct contact of the electrode and molten steel can generate a recarburization phenomenon, and the uniformity of components of a casting blank is influenced; finally, the temperature of the solidified shell affects the effectiveness of the electromagnetic stirrers, all the existing technologies do not consider the solution when the temperature of the shell is lower than the Curie point temperature, and the configured electromagnetic stirrers are generally of an integral structure with invariable size and cannot dynamically adjust the spacing according to the change of the size of the casting blank.
Aiming at the problems in the prior art, a novel vertical semi-continuous production device for large round billets with phi of 1000mm to phi 2000mm and a production process thereof are researched and designed, so that the problems in the prior art are very necessary to overcome.
Disclosure of Invention
The productivity proposed according to the above prior art is low; the energy consumption is high; large occupied area and investment; is not suitable for customized production; the core quality is difficult to control, and the problems of macro segregation, looseness, shrinkage cavity and the like are easy to occur; the quality control is difficult to realize, and the like, and provides a vertical semi-continuous production device of a large round billet with the diameter of 1000 mm-2000 mm and a production process thereof. The invention mainly adopts a plurality of ingot casting quality control technologies and is suitable for various steel types such as plain carbon steel, alloy steel and stainless steel materials, thereby effectively improving the quality level of related products.
The technical means adopted by the invention are as follows:
a vertical semi-continuous production device of a phi 1000 mm-phi 2000mm large round billet comprises: the system comprises a pipeline type induction heating ladle base, a pouring system, a cooling system, a casting blank lifting system, a split type electromagnetic stirring system, a casting blank temperature control system, a blank discharging system, a casting blank conveying slideway and a casting blank slow cooling system;
furthermore, the pipeline type induction heating ladle base is an auxiliary system of the pouring system;
furthermore, a pouring system, a cooling system and a casting blank lifting system are sequentially arranged from top to bottom;
furthermore, the split type electromagnetic stirring system and the casting blank temperature control system are arranged around the round blank as the casting blank quality control system;
further, the ejection system, the casting blank conveying slide way and the casting blank slow cooling system are sequentially arranged on one side of the production device.
Furthermore, the pouring system is compatible with two types of steel ladles, namely a common structure steel ladle and an induction heating steel ladle; the two types of steel ladles correspond to two types of pouring systems, which are respectively as follows: a common structure ladle casting system and an induction heating ladle casting system;
further, ordinary structure ladle gating system need not reform transform traditional ladle structure, includes: the device comprises a steel ladle with a common structure, a pipeline type induction heating steel ladle base, a steel ladle bracket, a long nozzle, a tundish and a rotational flow nozzle; the common structure ladle is connected with the pipeline type induction heating ladle base, is arranged on the ladle bracket together and is connected with the tundish through the long nozzle; the bottom of the tundish is provided with a rotational flow water gap which is immersed in molten steel of a cooling system, so that a flow channel for the molten steel to flow from a common structural steel ladle to the cooling system is formed;
further, an induction heating ladle pouring system includes: induction heating a steel ladle, a steel ladle bracket, a long nozzle, a tundish and a rotational flow nozzle; the induction heating ladle is arranged at the upper part of the ladle bracket and is connected with the tundish through the long nozzle; the bottom of the tundish is provided with a rotational flow water gap which is immersed in the molten steel of the cooling system, so that a flow channel for the molten steel to flow from the induction heating ladle to the cooling system is formed.
Furthermore, the upper part of the cooling system is connected with a pouring system, and the cooling system is divided into a crystallizer cooling area and a secondary cooling area which are arranged up and down;
further, the crystallizer cooling zone comprises: a crystallizer and a crystallizer vibration driving device;
further, the crystallizer is formed by surrounding a casting blank by a copper pipe, and the copper pipe is cooled by water;
further, a rotational flow water gap is inserted into the crystallizer;
further, the crystallizer vibration driving device is arranged outside the crystallizer;
furthermore, the secondary cooling area is composed of two groups of secondary cooling water spraying devices which are arranged around the casting blank and can spray water and water mist;
furthermore, four supporting foot rollers surrounding the casting blank are arranged between the two groups of secondary cooling water spray devices to support the casting blank. Through the forced cooling of the second cooling area, the solidified shell with higher density can be formed at an accelerated speed, the reduction of the structural strength of the shell caused by surface temperature return is effectively avoided, and the production safety is ensured.
Further, the casting blank lifting system is a core device for controlling the casting blank to move to each process operation position, and comprises: the dummy bar and the dummy bar hydraulic driving device;
furthermore, the outer diameter of the dummy bar is matched with the inner diameter of the crystallizer and can be inserted into the crystallizer;
furthermore, the top of the dummy bar is connected with the bottom of the solidified casting blank, and the dummy bar and the solidified casting blank are easy to separate during blank discharging;
furthermore, a dummy bar hydraulic driving device is connected with the bottom of the dummy bar and drives the dummy bar to drive the casting blank to move up and down;
furthermore, in the casting and drawing stage, the drawing speed is 0.005m/min-0.5m/min.
Furthermore, the split type electromagnetic stirring system is composed of a first group of electromagnetic stirrers and a second group of electromagnetic stirrers, wherein the first group of electromagnetic stirrers and the second group of electromagnetic stirrers are formed by pairwise opposite four independent split type electromagnetic stirrers;
further, the first group of electromagnetic stirrers and the second group of electromagnetic stirrers are arranged above and below and surround the casting blank;
furthermore, the first group of electromagnetic stirrers and the second group of electromagnetic stirrers are respectively provided with an independent lifting mechanism and move to corresponding working positions in cooperation with the process flow;
furthermore, the first group of electromagnetic stirrers and the second group of electromagnetic stirrers are also provided with a horizontal moving mechanism for controlling the distance between the first group of electromagnetic stirrers and the casting billets, and the distance between the first group of electromagnetic stirrers and the casting billets can be dynamically adjusted according to the diameter of each batch of casting billets;
further, in the pouring and pulling stage, the second group of electromagnetic stirrers synchronously move downwards along with the casting blank, the position of the solidification front is dynamically tracked, and the moving speed is 0.005m/min-0.5m/min.
Furthermore, in the standing and cooling stage, the first group of electromagnetic stirrers and the second group of electromagnetic stirrers move downwards synchronously along with the casting blank, dynamically track the position of the solidification front, and continuously rise along with the position, wherein the speed of rising movement is 0.005m/min-0.5m/min. Through the electromagnetic stirring at the tail end, the convection motion of the molten steel in a liquid-solid two-phase region at the tail end can be strengthened, and the effects of crushing dendritic crystals, improving feeding channels and homogenizing components are achieved.
Further, the casting blank temperature control system starts to work after the pouring is finished, and the casting blank temperature control system comprises: the device comprises an open-close type split heat insulation cover, a flame heating type temperature compensation device, a blank shell temperature measuring device and a movable induction heating riser heat insulation cover;
furthermore, the open-close type split heat-insulation cover is of a box body type structure made of light heat-insulation materials, 6-10 heat-insulation covers are arranged along the direction of blank drawing according to the length of a casting blank, all the heat-insulation covers are in an open state in the pouring stage, all the heat-insulation covers are closed after pouring is finished, and the heat-insulation covers are gradually opened by matching with the movement of a stirrer;
further, the flame heating type temperature compensation device and the blank shell temperature measurement system are arranged between the upper and lower open-close type split heat preservation covers and are matched for use; the flame heating type temperature compensating device is heated in a gas combustion mode, and the blank shell temperature measuring system is a non-contact infrared temperature measuring device;
furthermore, the movable induction heating riser heat-insulating cover is positioned on a platform above the crystallizer, the inner diameter of the movable induction heating riser heat-insulating cover is matched with the outer diameter of a casting blank, the movable induction heating riser heat-insulating cover can be moved to the position above the crystallizer by a moving device after pouring is finished, and the end of the casting blank riser is driven by a dummy bar hydraulic driving device to be lifted to the position above the platform and enters the movable induction heating riser heat-insulating cover for induction heating heat insulation.
Furthermore, the purpose of the casting blank temperature control system is to firstly reduce the temperature of the wall surface blank shell to be below the Curie temperature, shield a magnetic field produced by the electromagnetic stirrer, and secondly, effectively reduce the temperature difference between the inside and the outside of the casting blank, thereby reducing the casting stress and avoiding cracking.
Further, the ejection system comprises: the hydraulic rod and the casting blank grabbing and fixing mechanism;
furthermore, the casting blank grabbing and fixing mechanism grabs the casting blank and then realizes the turnover of the casting blank under the drive of the hydraulic rod, and the reversed casting blank is conveyed to a casting blank support in the casting blank slow cooling system through a conveying casting blank slide arranged outside the blank discharging system for heat preservation.
Furthermore, a Z-shaped channel with a circular cross section is designed inside the pipeline type induction heating ladle base, the upper inlet and the ladle with the common structure are connected with one of the induction heating ladles, and the lower outlet is connected with the long nozzle; a lifting lug is designed on the outer side of the pipeline type induction heating ladle base, and an induction heating coil is arranged outside the horizontal section, so that timely temperature compensation for molten steel under the condition of low drawing speed is realized.
Furthermore, the rotational flow water gap is a multi-opening water gap with a certain angle, and the molten steel naturally forms rotational flow when flowing out from the water gap, so that the fluidity of the molten steel in the crystallizer is improved, and the uniform distribution of components and temperature is realized.
The production process of the vertical semi-continuous production device for the large round billets with the diameter of phi 1000mm to phi 2000mm comprises the following steps:
1. a pouring preparation stage: inserting the hydraulically driven dummy bar into a crystallizer for a certain distance, lifting the first group of electromagnetic stirrers and the second group of electromagnetic stirrers to preset positions below a second cooling area, hoisting a steel ladle with a common structure onto a pipeline type induction heating steel ladle base, or hoisting the induction heating steel ladle onto a steel ladle bracket, and connecting the steel ladle with a tundish through a long nozzle;
2. and (3) casting and pulling: molten steel is poured into the crystallizer through a rotational flow water gap of the pouring system, a casting blank lifting system performs blank drawing, and a second group of electromagnetic stirrers synchronously descend along with the casting blank;
3. and (3) standing and cooling stage: stopping blank drawing when the length is preset, and entering a standing and cooling stage, wherein the split type electromagnetic stirring system and the casting blank temperature control system start to work;
4. and (3) a blank discharging slow cooling stage: and after the casting blank is completely solidified, the blank discharging system discharges the casting blank, and the casting blank is conveyed into the casting blank heat-insulating cover for slow cooling.
Compared with the prior art, the invention has the following advantages:
1. the vertical semi-continuous production device and the production process thereof for the large round billets with the diameter of 1000mm to 2000mm meet the ordering characteristic of single-batch and small-batch customized products for shaft parts in the industries of nuclear power, water and electricity and the like, effectively reduce the occupied area and production energy consumption of equipment of a main body, and can produce various high-quality special steel products;
2. the vertical semi-continuous production device and the production process thereof for the large round billets with the diameter of 1000 mm-2000 mm can effectively reduce the risk of hot cracking and cold cracking in the solidification process of the large round billets, can effectively inhibit component segregation and loose shrinkage cavity and improve the compactness of casting billets under the working action of a split type electromagnetic stirring system and a casting billet temperature control system, and the material utilization rate of the round billets can be improved to more than 90 percent
3. The vertical semi-continuous production device and the production process thereof for the large round billets with the diameter of 1000 mm-2000 mm can meet the production requirements of products with various specifications and can produce multi-specification round billets with the section diameter specification of 1000 mm-2000 mm and the length range of 5m-15 m.
In conclusion, the technical scheme of the invention solves the problems of low productivity in the prior art; the energy consumption is high; large occupied area and investment; is not suitable for customized production; the core quality is difficult to control, and the problems of macro segregation, looseness, shrinkage cavity and the like are easy to occur; quality control is difficult to realize, and the like.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a schematic diagram of a casting and blank drawing stage when a ladle with a common structure is adopted in the invention;
FIG. 2 is a schematic view of a portion of the upper platform of the present invention during a casting and pulling stage when an induction heating ladle is used;
FIG. 3 is a schematic illustration of the present invention during a still cool phase;
FIG. 4 is a schematic illustration of the ejection stage of the present invention;
FIG. 5 is a flow chart of the production process of the present invention.
In the figure: 1. the device comprises a common-structure steel ladle 2, an induction heating steel ladle 3, a pipeline type induction heating steel ladle base 4, a steel ladle support 5, a long nozzle 6, a tundish 7, a rotational flow nozzle 8, a crystallizer 9, a crystallizer vibration driving device 10, a secondary cooling water spraying device 11, a supporting foot roller 12, a dummy bar 13, a dummy bar hydraulic driving device 14, a casting blank 15, a first group of electromagnetic stirrers 16, a second group of electromagnetic stirrers 17, an open-close type split heat preservation cover 18, a flame heating type temperature compensation device 19, a blank shell temperature measuring device 20, a movable type induction heating riser heat preservation cover 21, a blank discharging system 22, an output casting blank slide 23, a casting blank slow cooling system 24 and a casting blank support.
Detailed Description
It should be noted that the embodiments and features of the embodiments of the present invention may be combined with each other without conflict. The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all the embodiments. The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses. All other embodiments, which can be obtained by a person skilled in the art without making any creative effort based on the embodiments in the present invention, belong to the protection scope of the present invention.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the invention. As used herein, the singular forms "a", "an", and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
The relative arrangement of the components and steps, the numerical expressions and numerical values set forth in these embodiments do not limit the scope of the present invention unless specifically stated otherwise. Meanwhile, it should be understood that the sizes of the respective portions shown in the drawings are not drawn in an actual proportional relationship for the convenience of description. Techniques, methods, and apparatus known to those of ordinary skill in the relevant art may not be discussed in detail but are intended to be part of the specification where appropriate. In all examples shown and discussed herein, any particular value should be construed as merely illustrative, and not limiting. Thus, other examples of the exemplary embodiments may have different values. It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, further discussion thereof is not required in subsequent figures.
In the description of the present invention, it is to be understood that the directions or positional relationships indicated by the directional terms such as "front, rear, upper, lower, left, right", "lateral, vertical, horizontal" and "top, bottom", etc., are generally based on the directions or positional relationships shown in the drawings for the convenience of description and simplicity of description, and that these directional terms, unless otherwise specified, do not indicate and imply that the device or element so referred to must have a particular orientation or be constructed and operated in a particular orientation, and therefore should not be considered as limiting the scope of the invention: the terms "inner and outer" refer to the inner and outer relative to the profile of the respective component itself.
For ease of description, spatially relative terms such as "over 8230 \ 8230;,"' over 8230;, \8230; upper surface "," above ", etc. may be used herein to describe the spatial relationship of one device or feature to another device or feature as shown in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is turned over, devices described as "above" or "on" other devices or configurations would then be oriented "below" or "under" the other devices or configurations. Thus, the exemplary terms "at 8230; \8230; 'above" may include both orientations "at 8230; \8230;' above 8230; 'at 8230;' below 8230;" above ". The device may be otherwise variously oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
It should be noted that the terms "first", "second", and the like are used to define the components, and are only used for convenience of distinguishing the corresponding components, and the terms have no special meanings unless otherwise stated, and therefore, the scope of the present invention should not be construed as being limited.
As shown in FIG. 1, the invention provides a vertical semi-continuous production device for a large round billet with phi 1000 mm-phi 2000mm, which comprises: the device comprises a pipeline type induction heating ladle base 3, a pouring system, a cooling system, a casting blank lifting system, a split type electromagnetic stirring system, a casting blank temperature control system, a blank discharging system 21, a casting blank conveying slide way 22 and a casting blank slow cooling system 23; the pipeline type induction heating ladle base 3 is an auxiliary system of a pouring system; the pouring system, the cooling system and the casting blank lifting system are sequentially arranged from top to bottom; the split type electromagnetic stirring system and the casting blank temperature control system are arranged around the round blank as the casting blank quality control system; the ejection system 21, the casting blank conveying slide way 22 and the casting blank slow cooling system 23 are sequentially arranged on one side of the production device.
As shown in fig. 1 and 2, the pouring system is compatible with two types of ladles, namely a common-structure ladle 1 and an induction heating ladle 2; the two types of steel ladles correspond to two types of pouring systems, which are respectively as follows: a common structure ladle casting system and an induction heating ladle casting system;
as shown in fig. 1, the conventional ladle casting system does not need to modify the conventional ladle structure, and includes: the device comprises a common-structure ladle 1, a pipeline type induction heating ladle base 3, a ladle support 4, a long nozzle 5, a tundish 6 and a rotational flow nozzle 7; the common structure ladle 1 is connected with the pipeline type induction heating ladle base 3, is arranged on the ladle bracket 4 together, and is connected with the tundish 6 through the long nozzle 5; the bottom of the tundish 6 is provided with a rotational flow water gap 7, and the rotational flow water gap 7 is immersed in molten steel of a cooling system, so that a flow channel for the molten steel from the common structure ladle 1 to the cooling system is formed;
as shown in fig. 1, the induction heating ladle pouring system includes: the method comprises the following steps of (1) inductively heating a steel ladle 2, a steel ladle bracket 4, a long nozzle 5, a tundish 6 and a rotational flow nozzle 7; the induction heating ladle 2 is arranged at the upper part of the ladle bracket 4 and is connected with the tundish 6 through the long nozzle 5; the bottom of the tundish 6 is provided with a swirl nozzle 7, and the swirl nozzle 7 is immersed in the molten steel of the cooling system, thereby forming a flow passage for the molten steel from the induction heating ladle 2 to the cooling system.
As shown in fig. 1-4, the upper part of the cooling system is connected with the gating system, and the cooling system is divided into a crystallizer cooling zone and a secondary cooling zone which are arranged up and down; the crystallizer cooling zone comprises: a crystallizer 8 and a crystallizer vibration driving device 9; the crystallizer 8 is formed by copper pipes surrounding the casting blank 14, and the copper pipes are cooled by water; a rotational flow water gap 7 is inserted into the crystallizer 8; the crystallizer vibration driving device 9 is arranged outside the crystallizer 8, and the crystallizer vibration driving device 9 is started before blank drawing; the secondary cooling area is composed of two groups of secondary cooling water spraying devices 10 which are arranged around the casting blank 14, and the secondary cooling water spraying devices 10 can spray water and water mist; four supporting foot rollers 11 surrounding the casting blank 14 are arranged between the two groups of secondary cooling water spray devices 10 to support the casting blank 14. Through the forced cooling of the second cooling area, the solidified shell with higher density can be formed at an accelerated speed, the reduction of the structural strength of the shell caused by surface temperature return is effectively avoided, and the production safety is ensured.
As shown in fig. 1, 3 and 4, the casting blank lifting system is a core device for controlling a casting blank to move to each process operation position, and comprises: a dummy bar 12 and a dummy bar hydraulic drive device 13; the outer diameter of the dummy bar 12 is matched with the inner diameter of the crystallizer 8, and the dummy bar can be inserted into the crystallizer 8; the top of the dummy bar 12 is connected with the bottom of the solidified casting blank 14, and the dummy bar and the solidified casting blank are easy to separate during blank ejection; the dummy bar hydraulic driving device 13 is connected with the bottom of the dummy bar 12 and drives the dummy bar 12 to drive the casting blank 14 to move up and down; when molten steel in the crystallizer 8 forms a blank shell with a certain thickness, the dummy bar 12 moves downwards, and a blank drawing state is started; in the casting and drawing stage, the drawing speed is 0.005m/min-0.5m/min.
As shown in fig. 1, the split type electromagnetic stirring system is composed of a first group of electromagnetic stirrers 15 and a second group of electromagnetic stirrers 16 which are formed by four independent split type electromagnetic stirrers which are opposite to each other in pairs; two groups of electromagnetic stirrers 15 and 16 are arranged around the casting blank 14, the first group of electromagnetic stirrers 15 is positioned below the second cold water spraying device 10, and the second group of electromagnetic stirrers 16 dynamically tracks the position of the solidification front all the time and continuously moves downwards along with the casting blank 14; the two groups of electromagnetic stirrers 15 and 16 are both provided with independent lifting mechanisms and move to corresponding working positions in cooperation with the process flow; the two groups of electromagnetic stirrers 15 and 16 are also provided with a horizontal moving mechanism for controlling the distance between the two groups of electromagnetic stirrers and the casting blank 14, and the distance between the two groups of electromagnetic stirrers and the casting blank can be dynamically adjusted according to the diameter of each batch of casting blank 14; in the pouring and throwing stage, the second group of electromagnetic stirrers 16 synchronously move downwards along with the casting blank 14, the position of the solidification front is dynamically tracked, and the moving speed is 0.005m/min-0.5m/min; in the standing and cooling stage, the first group of electromagnetic stirrers 15 and the second group of electromagnetic stirrers 16 both synchronously move downwards along with the casting blank 14, dynamically track the position of the solidification front, and continuously rise along with the position, wherein the speed of the rising movement is 0.005m/min-0.5m/min. Through the electromagnetic stirring at the tail end, the convection motion of the molten steel in a liquid-solid two-phase region at the tail end can be strengthened, and the effects of crushing dendritic crystals, improving feeding channels and homogenizing components are achieved.
As shown in fig. 1 and 3, the casting blank temperature control system starts to work after the pouring is finished, and comprises: an open-close type split heat insulation cover 17, a flame heating type temperature compensation device 18, a blank shell temperature measuring device 19 and a movable induction heating riser heat insulation cover 20; the open-close type split heat preservation cover 17 is of a box body type structure made of light heat preservation materials, 6-10 heat preservation covers are arranged along the direction of pulling according to the length of a casting blank, the heat preservation covers are all in an open state in the pouring stage, after pouring is completed, the heat preservation covers 17 are all closed when the first group of electromagnetic stirrers 15 are moved downwards to the same positions of the second group of electromagnetic stirrers 16, and the heat preservation covers are gradually opened by matching with the movement of the stirrers; in the standing and cooling stage, the positions of the first group of electromagnetic stirrers 15 and the second group of electromagnetic stirrers 16 dynamically track the solidification front and continuously rise, the rising moving speed is 0.005m/min-0.5m/min, and the open-close type split heat preservation covers 17 are opened one by one in coordination with the movement of the electromagnetic stirrers; the flame heating type temperature compensation device 18 and the blank shell temperature measuring system 19 are arranged between the upper and lower open-close type split heat insulation covers 17 and are matched for use; the flame heating type temperature compensating device 18 is heated in a gas combustion mode, and the blank shell temperature measuring system 19 is a non-contact infrared temperature measuring device; in the standing solidification stage, when the surface temperature of the billet shell is lower than the Curie point temperature, the flame heating type temperature compensation device 18 is started to heat the casting billet, and the surface temperature exceeds the Curie point temperature; the movable induction heating riser heat-insulating cover 20 is positioned on a platform above the crystallizer 8, the inner diameter of the movable induction heating riser heat-insulating cover is matched with the outer diameter of the casting blank 14, the movable induction heating riser heat-insulating cover 20 can be moved to the position above the crystallizer 8 by a moving device after the pouring is finished, and the riser end of the casting blank 14 is lifted to the position above the platform under the driving of the dummy bar hydraulic driving device 13 and enters the movable induction heating riser heat-insulating cover 20 for induction heating and heat insulation. The casting blank temperature control system aims to firstly reduce the temperature of the wall surface blank shell to be below the Curie temperature, shield a magnetic field produced by an electromagnetic stirrer, and secondly, effectively reduce the temperature difference between the inside and the outside of a casting blank, thereby reducing the casting stress and avoiding cracking.
As shown in fig. 1, 3 and 4, the ejection system 21 comprises: the hydraulic rod and the casting blank grabbing and fixing mechanism; when the casting blank 14 is completely solidified, the two groups of electromagnetic stirrers 15 and 16 are positioned below the secondary cooling zone, the casting blank 14 is driven by the dummy bar 12 to descend below the electromagnetic stirrers, and the process enters a blank discharging stage; the casting blank grabbing and fixing mechanism grabs the casting blank 14 and then realizes the turnover of the casting blank 14 under the driving of a hydraulic rod, and the reversed casting blank 14 is conveyed to a casting blank bracket 24 in a casting blank slow cooling system 23 through a casting blank conveying slide rail 22 arranged on the outer side of the blank ejection system 21 for heat preservation.
As shown in fig. 1, a zigzag channel with a circular cross section is designed inside a pipeline type induction heating ladle base 3, an upper inlet and a common structure ladle 1 are connected with one induction heating ladle 2, and a lower outlet is connected with a long nozzle 5; a lifting lug is designed on the outer side of the pipeline type induction heating ladle base 2, and the outside of the horizontal section is provided with an induction heating coil, so that the timely temperature compensation of the molten steel under the condition of slower drawing speed is realized.
As shown in fig. 1 and 2, the swirl nozzle 7 is a multi-opening nozzle having a certain angle, and when molten steel flows out from the nozzle, a swirl flow is naturally formed, so that the fluidity of molten steel in a mold is improved, and the uniform distribution of components and temperature is realized.
As shown in fig. 5, a production process of a vertical semi-continuous production device for large round billets with phi of 1000mm to phi 2000 mm; the method is characterized in that: the production process comprises the following steps:
1. a pouring preparation stage: inserting the hydraulically driven dummy bar 12 into the crystallizer 8 for a certain distance, lifting the first group of electromagnetic stirrers 15 and the second group of electromagnetic stirrers 16 to a preset position below a secondary cooling zone, lifting the steel ladle 1 with a common structure onto a pipeline type induction heating steel ladle base 3, or lifting the induction heating steel ladle 2 onto a steel ladle bracket 4, and connecting the steel ladle 2 with the tundish 6 through a long nozzle 5;
2. pouring and pulling: molten steel is poured into the crystallizer 8 through a rotational flow water gap 7 of the pouring system, a casting blank lifting system performs blank drawing, and the second group of electromagnetic stirrers 16 synchronously descend along with the casting blank 14;
3. and (3) standing and cooling stage: stopping blank drawing when the length is preset, entering a standing and cooling stage, and starting the work of the split type electromagnetic stirring system and the casting blank temperature control system;
4. and (3) blank discharging and slow cooling stage: after the casting blank is completely solidified, the casting blank discharging system 21 discharges the casting blank, and the casting blank 14 is conveyed into the casting blank heat-insulating cover 23 for slow cooling.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and these modifications or substitutions do not depart from the spirit of the corresponding technical solutions of the embodiments of the present invention.
Claims (8)
1. A vertical semi-continuous production device for large round billets with phi of 1000mm to phi 2000 mm; the method is characterized in that:
the vertical semi-continuous production device of the phi 1000 mm-phi 2000mm large round billet comprises: the device comprises a pipeline type induction heating ladle base (3), a pouring system, a cooling system, a casting blank lifting system, a split type electromagnetic stirring system, a casting blank temperature control system, a blank discharging system (21), a casting blank conveying slide way (22) and a casting blank slow cooling system (23);
the pipeline type induction heating ladle base (3) is an auxiliary system of a pouring system;
the pouring system, the cooling system and the casting blank lifting system are sequentially arranged from top to bottom;
the split type electromagnetic stirring system and the casting blank temperature control system are arranged around the round blank as a casting blank quality control system;
the split type electromagnetic stirring system is composed of a first group of electromagnetic stirrers (15) and a second group of electromagnetic stirrers (16), wherein the first group of electromagnetic stirrers and the second group of electromagnetic stirrers are formed by four independent electromagnetic stirrers which are opposite in pairs;
the first group of electromagnetic stirrers (15) and the second group of electromagnetic stirrers (16) are arranged up and down and are arranged around the casting blank (14);
the first group of electromagnetic stirrers (15) and the second group of electromagnetic stirrers (16) are respectively provided with an independent lifting mechanism and move to corresponding working positions in cooperation with a process flow;
the first group of electromagnetic stirrers (15) and the second group of electromagnetic stirrers (16) are also provided with a horizontal moving mechanism for controlling the distance between the horizontal moving mechanism and the casting billets (14), and the distance between the horizontal moving mechanism and the casting billets can be dynamically adjusted according to the diameter of each batch of casting billets (14);
in the pouring and pulling stage, the second group of electromagnetic stirrers (16) synchronously move downwards along with the casting blank (14), the position of the solidification front is dynamically tracked, and the moving speed is 0.005m/min-0.5m/min;
in the standing and cooling stage, the first group of electromagnetic stirrers (15) move downwards to the same positions as the second group of electromagnetic stirrers (16), and dynamically track the position of the solidification front together with the second group of electromagnetic stirrers (16), the position of the solidification front continuously rises along with the movement of the solidification front, and the speed of the rising movement is 0.005m/min-0.5m/min;
the casting blank temperature control system starts to work after pouring is finished, and the casting blank temperature control system comprises: an open-close type split heat insulation cover (17), a flame heating type temperature compensation device (18), a blank shell temperature measuring device (19) and a movable induction heating riser heat insulation cover (20);
the open-close type split heat preservation cover (17) is of a box type structure made of light heat preservation materials, 6-10 heat preservation covers are arranged along the billet drawing direction according to the length of a casting billet, the heat preservation covers are all in an open state in the casting stage, after casting is completed, the first group of electromagnetic stirrers (15) are moved downwards to the same positions as the second group of electromagnetic stirrers (16), all the electromagnetic stirrers are closed, and the heat preservation covers are gradually opened in the standing and cooling stage in cooperation with the movement of the first group of electromagnetic stirrers (15) and the second group of electromagnetic stirrers (16);
the flame heating type temperature compensation device (18) and the blank shell temperature measuring device (19) are arranged between the adjacent upper and lower open-close type split heat insulation covers (17), and the flame heating type temperature compensation device (18) and the blank shell temperature measuring device (19) are matched for use; the flame heating type temperature compensation device (18) is heated in a gas combustion mode, and the blank shell temperature measuring device (19) is a non-contact infrared temperature measuring device;
the movable induction heating riser heat-insulating cover (20) is positioned on a platform above the crystallizer (8), the inner diameter of the movable induction heating riser heat-insulating cover is matched with the outer diameter of a casting blank (14), after the casting is finished, the movable induction heating riser heat-insulating cover (20) is moved to the position above the crystallizer (8) by a moving device, and the riser end of the casting blank (14) is driven by an ingot rod hydraulic driving device (13) of a casting blank lifting system to be lifted to the position above the platform and enters the movable induction heating riser heat-insulating cover (20) for induction heating and heat insulation;
the ejection system (21), the casting blank conveying slide way (22) and the casting blank slow cooling system (23) are sequentially arranged on one side of the production device.
2. The vertical semi-continuous production device of the large round billets with the diameter phi of 1000mm to 2000mm as claimed in claim 1, which is characterized in that:
the gating system comprises two gating systems which are respectively: a common structure ladle casting system and an induction heating ladle casting system;
the common structure ladle gating system does not need to reform the conventional ladle structure and comprises the following components: a common-structure ladle (1), a pipeline type induction heating ladle base (3), a ladle bracket (4), a long nozzle (5), a tundish (6) and a rotational flow nozzle (7); the common-structure ladle (1) is connected with the pipeline type induction heating ladle base (3), is arranged on the ladle bracket (4) together, and is connected with the tundish (6) through the long nozzle (5); the bottom of the tundish (6) is provided with a rotational flow water gap (7), and the rotational flow water gap (7) is immersed in molten steel of a cooling system, so that a flow channel for the molten steel to flow from the common-structure ladle (1) to the cooling system is formed;
the induction heating ladle pouring system comprises: the device comprises an induction heating ladle (2), a ladle bracket (4), a long nozzle (5), a tundish (6) and a rotational flow nozzle (7); the induction heating ladle (2) is arranged at the upper part of the ladle bracket (4) and is connected with the tundish (6) through the long nozzle (5); the bottom of the tundish (6) is provided with a rotational flow water gap (7), and the rotational flow water gap (7) is immersed in molten steel of a cooling system, so that a flow channel for the molten steel to flow from the induction heating ladle (2) to the cooling system is formed.
3. The vertical semi-continuous production device of the large round billets with the diameter phi of 1000mm to 2000mm as claimed in claim 2, characterized in that:
the upper part of the cooling system is connected with a pouring system, and the cooling system is divided into a crystallizer cooling area and a secondary cooling area which are arranged up and down;
the cooling zone of the crystallizer comprises: a crystallizer (8) and a crystallizer vibration driving device (9);
the crystallizer (8) is formed by surrounding a casting blank (14) by a copper pipe, and the copper pipe is cooled by water;
a rotational flow water gap (7) is inserted into the crystallizer (8);
the crystallizer vibration driving device (9) is arranged outside the crystallizer (8);
the secondary cooling area is composed of two groups of secondary cooling water spraying devices (10) which are arranged around the casting blank (14), and the secondary cooling water spraying devices (10) spray water and water mist;
four supporting foot rollers (11) surrounding the casting blank (14) are arranged between the two groups of secondary cooling water spray devices (10) to support the casting blank (14).
4. The vertical semi-continuous production device of the large round billets with the diameter phi of 1000mm to 2000mm as claimed in claim 3, characterized in that:
the casting blank lifting system is core equipment for controlling a casting blank to move to each process operation position, and comprises: a dummy bar (12) and a dummy bar hydraulic drive device (13);
the outer diameter of the dummy bar (12) is matched with the inner diameter of the crystallizer (8) and can be inserted into the crystallizer (8);
the top of the dummy bar (12) is connected with the bottom of the solidified casting blank (14), and the dummy bar and the solidified casting blank are easy to separate during ejection;
the dummy bar hydraulic driving device (13) is connected with the bottom of the dummy bar (12) and drives the dummy bar (12) to drive the casting blank (14) to move up and down;
in the casting and drawing stage, the drawing speed is 0.005m/min-0.5m/min.
5. The vertical semi-continuous production device of the large round billets with the diameter phi of 1000mm to 2000mm as claimed in claim 1, which is characterized in that:
the ejection system (21) comprises: the hydraulic rod and the casting blank grabbing and fixing mechanism;
the casting blank grabbing and fixing mechanism grabs the casting blank (14) and then realizes the turnover of the casting blank (14) under the driving of a hydraulic rod, and the reversed casting blank (14) is conveyed to a casting blank bracket (24) in a casting blank slow cooling system (23) through a casting blank conveying slide way (22) arranged on the outer side of a blank discharging system (21) for heat preservation.
6. The vertical semi-continuous production device of the phi 1000 mm-phi 2000mm large-scale round billet according to claim 2, characterized in that:
a Z-shaped channel with a circular section is designed inside the pipeline type induction heating ladle base (3), the upper inlet of the Z-shaped channel is connected with one of a common structure ladle (1) or an induction heating ladle (2), and the lower outlet of the Z-shaped channel is connected with the long nozzle (5); a lifting lug is designed on the outer side of the pipeline type induction heating ladle base (3), and an induction heating coil is arranged outside the horizontal section of the Z-shaped channel.
7. The vertical semi-continuous production device of the large round billets with the diameter phi of 1000mm to 2000mm as claimed in claim 2, characterized in that:
the rotational flow water gap (7) is a multi-opening water gap with a certain angle, and the molten steel naturally forms rotational flow when flowing out from the water gap, so that the fluidity of the molten steel in the crystallizer is improved, and the uniform distribution of components and temperature is realized.
8. The production process of the vertical semi-continuous production device of the large round billet with the diameter of between 1000 and 2000mm according to claim 4; the method is characterized in that: the production process comprises the following steps:
101. a pouring preparation stage: inserting a dummy bar (12) into a crystallizer (8) for a certain distance, lifting the first group of electromagnetic stirrers (15) and the second group of electromagnetic stirrers (16) to a preset position below a second cooling area, hoisting the steel ladle (1) with the common structure to a pipeline type induction heating steel ladle base (3), or hoisting the induction heating steel ladle (2) to a steel ladle bracket (4), and connecting the steel ladle with a tundish (6) through a long nozzle (5);
102. and (3) casting and pulling: molten steel is poured into a crystallizer (8) through a rotational flow water gap (7) of the pouring system, a casting blank lifting system performs blank drawing, and a second group of electromagnetic stirrers (16) synchronously descend along with a casting blank (14);
103. and (3) standing and cooling stage: stopping blank drawing when the casting blank reaches a preset length, entering a standing and cooling stage, and starting the work of the split type electromagnetic stirring system and the casting blank temperature control system;
104. and (3) a blank discharging slow cooling stage: after the casting blank is completely solidified, the blank discharging system (21) discharges the casting blank, and the casting blank (14) is conveyed into the casting blank slow cooling system (23) for slow cooling.
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| CN115194111A (en) * | 2022-07-21 | 2022-10-18 | 武汉大西洋连铸设备工程有限责任公司 | Semi-continuous casting vertical casting process and equipment for large round billet to extra-large round billet |
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| JP4332982B2 (en) * | 2000-03-24 | 2009-09-16 | 日立金属株式会社 | Manufacturing method of iron-based alloy magnet |
| JP4613448B2 (en) * | 2001-06-01 | 2011-01-19 | 大同特殊鋼株式会社 | Vertical casting method and apparatus |
| JP4678592B2 (en) * | 2005-10-21 | 2011-04-27 | 日立金属株式会社 | Continuous casting equipment |
| DE102006056683A1 (en) * | 2006-01-11 | 2007-07-12 | Sms Demag Ag | Continuous casting of metal profiles, first cools cast strip then permits thermal redistribution to re-heat surface before mechanical deformation |
| CN101428335B (en) * | 2008-12-01 | 2011-11-02 | 江阴兴澄特种钢铁有限公司 | Continuous casting method for producing round blank with diameter larger than Phi800m on straight continuous casting machine |
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| KR101511723B1 (en) * | 2013-03-15 | 2015-04-13 | 주식회사 포스코 | Casting apparatus and method using it |
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