EP3028790A1 - Procédé de coulée continue par étirage ascendant - Google Patents

Procédé de coulée continue par étirage ascendant Download PDF

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Publication number
EP3028790A1
EP3028790A1 EP14832044.3A EP14832044A EP3028790A1 EP 3028790 A1 EP3028790 A1 EP 3028790A1 EP 14832044 A EP14832044 A EP 14832044A EP 3028790 A1 EP3028790 A1 EP 3028790A1
Authority
EP
European Patent Office
Prior art keywords
pulling
acceleration
speed
starter
metal
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP14832044.3A
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German (de)
English (en)
Inventor
Naoaki Sugiura
Yusuke Yokota
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toyota Motor Corp
Original Assignee
Toyota Motor Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Toyota Motor Corp filed Critical Toyota Motor Corp
Publication of EP3028790A1 publication Critical patent/EP3028790A1/fr
Withdrawn legal-status Critical Current

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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
    • B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • B22D11/041—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds for vertical casting
    • 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
    • B22D11/01—Continuous casting of metals, i.e. casting in indefinite lengths without moulds, e.g. on molten surfaces
    • 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
    • B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • 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
    • B22D11/145—Plants for continuous casting for upward casting

Definitions

  • the present invention relates to a pulling-up-type continuous casting method.
  • Patent Literature 1 proposed a free casting method as a revolutionary pulling-up-type continuous casting method that does not requires any mold.
  • a starter is submerged into the surface of a melted metal (molten metal) (i.e., molten-metal surface)
  • the starter is pulled up, so that some of the molten metal follows the starter and is drawn by the starter by the surface film of the molten metal and/or the surface tension.
  • molten metal molten metal
  • the shape in the longitudinal direction as well as the shape in cross section is defined by the mold.
  • the cast-metal article since the solidified metal (i.e., cast-metal article) needs to pass through inside the mold, the cast-metal article has a shape extending on a straight-line in the longitudinal direction.
  • Patent Literature 1 discloses a hollow cast-metal article (i.e., a pipe) having a zigzag shape or a helical shape in the longitudinal direction rather than the straight-line shape.
  • Patent Literature 1 Japanese Unexamined Patent Application Publication No. 2012-61518
  • the present inventors have found the following problem.
  • a cooling gas is blown on cast metal following the starter immediately after the cast metal is solidified and the molten metal is thereby indirectly cooled.
  • the casting process needs to be advanced in a state where the speed at which the solidification advances from the top toward the bottom of the cast metal (hereinafter called a "solidifying speed") is substantially equal to the pulling-up speed. For example, if only the pulling-up speed is increased while maintaining the cooling power for the pulled-up molten metal unchanged (i.e., while maintaining the solidifying speed unchanged), the solidification interface rises and hence the pulled-up molten metal is torn apart. That is, if the cooling power is determined, an appropriate pulling-up speed corresponding to that cooling power is determined. Note that to increase the pulling-up speed and thereby improve productivity, the above-described cooling power needs to be increased.
  • the starter is accelerated from a standstill state to a desired pulling-up speed (i.e., the above-described appropriate pulling-up speed corresponding to the cooling power).
  • a desired pulling-up speed i.e., the above-described appropriate pulling-up speed corresponding to the cooling power.
  • the acceleration for the pulling-up operation is too high, the molten metal pulled-up by the starter is torn apart before the pulling-up speed of the starter reaches the desired pulling-up speed, thus making the casting itself impossible.
  • the acceleration for the pulling-up operation is lowered in order to prevent the molten metal from being torn apart due to the acceleration, it takes time before the pulling-up speed of the starter reaches the desired pulling-up speed, thus deteriorating productivity.
  • the present invention has been made in view of the above-described problems, and an object thereof is to provide a pulling-up-type continuous casting method that has excellent productivity while preventing the pulled-up molten metal from being torn apart during the acceleration.
  • a pulling-up-type continuous casting method according to an aspect of the present invention is
  • This configuration can provide a pulling-up-type continuous casting method that has excellent productivity while preventing the pulled-up molten metal from being torn apart during the acceleration.
  • the first acceleration is preferably an acceleration that will cause a tearing in the molten metal pulled-up by the starter before the pulling-up speed of the starter reaches the predetermined pulling-up speed if the starter is continuously accelerated from the standstill state at that acceleration
  • the second acceleration is preferably an acceleration that will cause a tearing in the molten metal pulled-up by the starter before the pulling-up speed of the starter reaches the predetermined pulling-up speed if the starter is continuously accelerated from the standstill state at that acceleration. It is possible to improve productivity even further.
  • first and second accelerations are preferably equal to each other.
  • each of the first and second accelerations is particularly preferably a maximum acceleration that a pulling-up machine that pulls up the starter can deliver.
  • the pulling-up-type continuous casting method may further include a third acceleration section in which the starter is accelerated from the second speed to a third speed at a third acceleration, and a constant speed section in which the starter is pulled up at the second speed, the constant speed section being positioned between the second and third acceleration sections.
  • the second acceleration may be higher than the first acceleration.
  • the second acceleration is preferably a maximum acceleration that a pulling-up machine that pulls up the starter can deliver.
  • Fig. 1 is a schematic cross section of a free casting apparatus according to the first exemplary embodiment.
  • the free casting apparatus according to the first exemplary embodiment includes a molten-metal holding furnace 101, a shape defining member 102, a support rod 104, an actuator 105, a cooling gas nozzle(s) 106, and a pulling-up machine 108.
  • the xyplane forms a horizontal plane and the z-axis direction is the vertical direction. More specifically, the positive direction on the z-axis is the vertically upward direction.
  • the molten-metal holding furnace 101 contains molten metal M1 such as aluminum or its alloy, and maintains the molten metal M1 at a predetermined temperature at which the molten metal M1 has fluidity.
  • molten metal M1 such as aluminum or its alloy
  • the surface of molten metal M1 i.e., molten-metal surface
  • the molten-metal holding furnace 101 may be replenished with molten metal as required during the casting process so that the molten-metal surface is kept at a fixed level.
  • the position of the solidification interface SIF can be raised by increasing the setting temperature of the holding furnace and the position of the solidification interface SIF can be lowered by lowering the setting temperature of the holding furnace.
  • the molten metal M1 may be a metal or an alloy other than aluminum.
  • the shape defining member 102 is made of ceramic or stainless steel, for example, and disposed near the molten-metal surface. In the example shown in Fig. 1 , the shape defining member 102 is disposed so that its underside principal surface (undersurface) is in contact with the molten-metal surface.
  • the shape defining member 102 can define the cross-sectional shape of cast metal M3 to be cast while preventing oxide films formed on the surface of the molten metal M1 and foreign substances floating on the surface of the molten metal M1 from entering the cast metal M3.
  • the cast metal M3 shown in Fig. 1 is a solid cast-metal article having a platelike shape in a horizontal cross section (hereinafter referred to as "lateral cross section"). Note that needless to say, there is no particular restriction on the cross-sectional shape of the cast metal M3.
  • the cast metal M3 may be, for example, a hollow cast-metal article such as a circular pipe and a rectangular pipe.
  • Fig. 2 is a plane view of the shape defining member 102 according to the first exemplary embodiment.
  • the cross section of the shape defining member 102 shown in Fig. 1 corresponds to a cross section taken along the line I-I in Fig. 2 .
  • the shape defining member 102 has, for example, a rectangular shape as viewed from the top, and has a rectangular opening (molten-metal passage section 103) having a thickness t1 and a width w1 at the center thereof. The molten metal passes through the rectangular opening (molten-metal passage section 103).
  • the molten metal M1 follows the cast metal M3 and is pulled up by the cast metal M3 by its surface film, the surface tension, and the like. Further, the molten metal M1 passes through the molten-metal passage section 103 of the shape defining member 102. That is, as the molten metal M1 passes through the molten-metal passage section 103 of the shape defining member 102, an external force is applied from the shape defining member 102 to the molten metal M1 and the cross-sectional shape of the cast metal M3 is thereby defined.
  • the molten metal that follows the cast metal M3 and is pulled up from the molten-metal surface by the surface film of the molten metal, the surface tension, and the like is called "held molten metal M2". Further, the boundary between the cast metal M3 and the held molten metal M2 is the solidification interface SIF.
  • the support rod 104 supports the shape defining member 102.
  • the support rod 104 is connected to the actuator 105.
  • the shape defining member 102 can be moved in the up/down direction (vertical direction) and in the horizontal direction through the support rod 104.
  • the shape defining member 102 can be moved in the horizontal direction, the shape in the longitudinal direction of the cast metal M3 can be changed.
  • the cooling gas nozzle (cooling unit) 106 is cooling means for blowing a cooling gas (such as air, nitrogen, and argon) supplied from a cooling gas supply unit (not shown) on the cast metal M3 and thereby cooling the cast metal M3.
  • a cooling gas such as air, nitrogen, and argon
  • the position of the solidification interface SIF can be lowered by increasing the flow rate of the cooling gas and can be raised by reducing the flow rate of the cooling gas.
  • the cooling gas nozzle (cooling unit) 106 can also be moved in the horizontal direction and in the vertical direction in accordance with the movement of the shape defining member 102.
  • the held molten metal M2 located in the vicinity of the solidification interface SIF is successively solidified, and the cast metal M3 is thereby formed.
  • the position of the solidification interface SIF can be raised by increasing the pulling-up speed of the pulling-up machine 108 and can be lowered by reducing the pulling-up speed.
  • the starter ST is lowered and made to pass through the molten-metal passage section 103 of the shape defining member 102, and the tip of the starter ST is submerged into the molten metal M1.
  • the starter ST starts to be pulled up at a predetermined speed.
  • the molten metal M1 follows the starter ST and is pulled up from the molten-metal surface by the surface film, the surface tension, and the like, thus forming the held molten metal M2.
  • the held molten metal M2 is formed in the molten-metal passage section 103 of the shape defining member 102. That is, the held molten metal M2 is shaped into a given shape by the shape defining member 102.
  • the pulling-up speed is accelerated (i.e., increased) from a standstill state to a desired pulling-up speed (i.e., an appropriate pulling-up speed corresponding to cooling power by the cooling gas nozzle 106).
  • a desired pulling-up speed i.e., an appropriate pulling-up speed corresponding to cooling power by the cooling gas nozzle 106.
  • Fig. 3 is a schematic graph showing a pulling-up speed acceleration method according to the first exemplary embodiment.
  • the horizontal axis indicates the time and the vertical axis indicates the pulling-up speed (mm/s).
  • a case where the starter is continuously accelerated at an acceleration a1 is indicated by an alternate long and short dash line for a comparison.
  • a tearing occurs in the held molten metal M2 before the pulling-up speed of the starter reaches a maximum pulling-up speed Vmax, which is the appropriate pulling-up speed corresponding to the cooling power by the cooling gas nozzle 106.
  • the acceleration a1 is, for example, the maximum acceleration that the pulling-up machine 108 can deliver.
  • a tearing occurs in the held molten metal M2 at the point when the pulling-up speed reaches a speed V1.
  • the acceleration a2 is the maximum acceleration at which the pulling-up speed can reach the maximum pulling-up speed Vmax without causing any tearing in the held molten metal M2 even when the starter is continuously accelerated from the standstill state at that acceleration. That is, if the starter is continuously accelerated from the standstill state at an acceleration higher than the acceleration a2, a tearing occurs in the held molten metal M2 before the pulling-up speed reaches the maximum pulling-up speed Vmax.
  • the pulling-up speed can reach the maximum pulling-up speed Vmax without causing any tearing in the held molten metal M2.
  • the pulling-up speed reaches the maximum pulling-up speed Vmax at a time t2. Therefore, productivity is poor.
  • a constant-speed operation section is provided between acceleration operation sections in order to improve productivity while preventing the held molten metal M2 from being torn apart.
  • the pulling-up operation is switched from the acceleration operation, in which the starter is accelerated at the acceleration a1, to the constant-speed operation before the pulling-up speed reaches the speed V1 at which a tearing would otherwise occur in the held molten metal M2.
  • the pulling-up operation is switched to the constant-speed operation at the point when the pulling-up speed reaches a speed V11 ( ⁇ V1). Note that the speed V11 is lower than the maximum pulling-up speed Vmax corresponding to the cooling power. Therefore, the position of the solidification interface SIF is lowered in the constant-speed operation section in which the starter is pulled up at the speed V11.
  • the pulling-up operation is switched from the constant-speed operation to the acceleration operation in which the starter is accelerated at the acceleration a1 again.
  • the acceleration in this acceleration operation section does not necessarily have to be equal to the acceleration in the previous acceleration operation section.
  • the accelerations in both of the acceleration operation sections are preferably higher than the acceleration a2 in view of the resulting improvement in productivity.
  • the acceleration in the acceleration operation section is preferably an acceleration that will cause a tearing in the held molten metal M2 before the pulling-up speed reaches the maximum pulling-up speed Vmax if the starter is continuously accelerated from the standstill state at that acceleration.
  • the pulling-up operation is switched to a constant-speed operation again at the point when the pulling-up speed reaches a speed V12 (> V1).
  • the pulling-up operation is switched to an acceleration operation in which the starter is accelerated at the acceleration a1 again and the pulling-up speed is eventually increased to the maximum pulling-up speed Vmax.
  • two constant-speed operation sections are provided.
  • the number of constant-speed operation sections is preferably as small as possible in view of productivity.
  • a plurality of constant-speed operation sections may be provided in order to increase the pulling-up speed to the maximum pulling-up speed Vmax while preventing the held molten metal M2 from being torn apart.
  • productivity can be improved by reducing the length of each constant-speed operation section.
  • the constant-speed operation section is too short, the position of the solidification interface SIF is not sufficiently lowered in the constant-speed operation section. As a result, a tearing is likely to occur in the held molten metal M2 when the pulling-up operation is switched to the acceleration operation.
  • the starter is accelerated at an acceleration that is higher than the acceleration a2 at which no tearing occurs in the held molten metal M2 even when the starter is continuously accelerated at that acceleration. Therefore, as shown in Fig. 3 , the pulling-up speed reaches the maximum pulling-up speed Vmax at a time t1 ( ⁇ t2). Therefore, productivity is excellent.
  • Fig. 4 is a schematic graph showing a pulling-up speed acceleration method according to the modified example 1 of the first exemplary embodiment.
  • the pulling-up operation is switched to the constant-speed operation at the point when the pulling-up speed reaches a speed V21 that is higher than the speed V1 and lower than the speed V2. That is, in the example shown in Fig. 4 , while the acceleration is lower than that in the example shown in Fig. 3 , the number of constant-speed operation sections is only one. As shown above, the number of constant-speed operation sections is preferably optimized according to the acceleration. Further, the casting process is preferably started with the acceleration a3, which is lower than the acceleration a1, because a tearing is more likely to occur in the held molten metal M2 immediately after the casting process is started.
  • Fig. 5 is a schematic graph showing a pulling-up speed acceleration method according to the modified example 2 of the first exemplary embodiment.
  • the acceleration before the constant-speed operation section and the acceleration after the constant-speed operation section are both the acceleration a3.
  • the acceleration after the constant-speed operation section is the acceleration a1, which is higher than the acceleration a3 which is the acceleration before the constant-speed operation section.
  • a constant-speed operation section(s) is provided between acceleration operations at the start of the casting. This can prevent the held molten metal M2 from being torn apart even when the starter is accelerated at an acceleration that will cause a tearing in the held molten metal M2 if the starter is continuously accelerated at that acceleration. Further, the pulling-up speed can be increased to the maximum pulling-up speed Vmax in a shorter time period than the time period that is required in the related art. Therefore, productivity is excellent.
  • Fig. 6 is a plan view of a shape defining member 102 according to the second exemplary embodiment.
  • Fig. 7 is a side view of the shape defining member 102 according to the second exemplary embodiment. Note that the xyz-coordinate systems shown in Figs. 6 and 7 correspond to that shown in Fig. 1 .
  • the shape defining member 102 according to the first exemplary embodiment shown in Fig. 2 is composed of one plate. Therefore, the thickness t1 and the width w1 of the molten-metal passage section 103 are fixed.
  • the shape defining member 102 according to the second exemplary embodiment includes four rectangular shape defining plates 102a, 102b, 102c and 102d as shown in Fig. 6 . That is, the shape defining member 102 according to the second exemplary embodiment is divided into a plurality of sections. With this configuration, it is possible to change the thickness t1 and the width w1 of the molten-metal passage section 103. Further, the four rectangular shape defining plates 102a, 102b, 102c and 102d can be moved in unison in the z-axis direction.
  • the shape defining plates 102a and 102b are arranged to be opposed to each other in the x-axis direction. Further, as shown in Fig. 7 , the shape defining plates 102a and 102b are disposed at the same height in the z-axis direction. The gap between the shape defining plates 102a and 102b defines the width w1 of the molten-metal passage section 103. Further, since each of the shape defining plates 102a and 102b can be independently moved in the x-axis direction, the width w1 can be changed. Note that, as shown in Figs. 6 and 7 , a laser displacement gauge S1 and a laser reflector plate S2 may be provided on the shape defining plates 102a and 102b, respectively, in order to measure the width w1 of the molten-metal passage section 103.
  • the shape defining plates 102c and 102d are arranged to be opposed to each other in the y-axis direction. Further, the shape defining plates 102c and 102c are disposed at the same height in the z-axis direction. The gap between the shape defining plates 102c and 102d defines the thickness t1 of the molten-metal passage section 103. Further, since each of the shape defining plates 102c and 102d can be independently moved in the y-axis direction, the thickness t1 can be changed.
  • the shape defining plates 102a and 102b are disposed in such a manner that they are in contact with the top sides of the shape defining plates 102c and 102d.
  • the driving mechanism for the shape defining plate 102a includes slide tables T1 and T2, linear guides G11, G12, G21 and G22, actuators A1 and A2, and rods R1 and R2.
  • the shape defining plates 102b, 102c and 102d also includes its driving mechanism as in the case of the shape defining plate 102a, the illustration of them is omitted in Figs. 6 and 7 .
  • the shape defining plate 102a is placed and fixed on the slide table T1, which can be slid in the x-axis direction.
  • the slide table T1 is slidably placed on a pair of linear guides G11 and G12 extending in parallel with the x-axis direction. Further, the slide table T1 is connected to the rod R1 extending from the actuator A1 in the x-axis direction.
  • the shape defining plate 102a can be slid in the x-axis direction.
  • the linear guides G11 and G12 and the actuator A1 are placed and fixed on the slide table T2, which can be slid in the z-axis direction.
  • the slide table T2 is slidably placed on a pair of linear guides G21 and G22 extending in parallel with the z-axis direction. Further, the slide table T2 is connected to the rod R2 extending from the actuator A2 in the z-axis direction.
  • the linear guides G21 and G22 and the actuator A2 are fixed on a horizontal floor surface or a horizontal pedestal (not shown). With the above-described configuration, the shape defining plate 102a can be slid in the z-axis direction.
  • the actuators A1 and A2 include a hydraulic cylinder, an air cylinder, and a motor.
  • the shape of the molten-metal passage section 103 can be changed. Therefore, the cross-sectional shape of the cast metal M3 can be changed during the casting process.
  • control may be performed so that the shape of the molten-metal passage section 103 is reduced in size in the acceleration operation section at the start of the casting.
  • the tearing in the held molten metal M2 can be prevented or reduced even further by reducing the mass of the held molten metal M2.
  • the present invention can be applied to a pulling-up-type continuous casting method in which the shape defining member 102 is not used, provided that the molten metal is pulled up by using a starter ST in the pulling-up-type continuous casting method.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
EP14832044.3A 2013-07-30 2014-06-05 Procédé de coulée continue par étirage ascendant Withdrawn EP3028790A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2013158202A JP6003840B2 (ja) 2013-07-30 2013-07-30 引上式連続鋳造方法
PCT/JP2014/003010 WO2015015686A1 (fr) 2013-07-30 2014-06-05 Procédé de coulée continue par étirage ascendant

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EP3028790A1 true EP3028790A1 (fr) 2016-06-08

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EP14832044.3A Withdrawn EP3028790A1 (fr) 2013-07-30 2014-06-05 Procédé de coulée continue par étirage ascendant

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US (1) US20160158833A1 (fr)
EP (1) EP3028790A1 (fr)
JP (1) JP6003840B2 (fr)
KR (1) KR20160018784A (fr)
CN (1) CN105392579A (fr)
WO (1) WO2015015686A1 (fr)

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KR102237422B1 (ko) * 2020-05-08 2021-04-08 제일기술산업(주) 로딩암의 작업 범위 감지 모니터링 시스템

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Publication number Publication date
WO2015015686A1 (fr) 2015-02-05
JP6003840B2 (ja) 2016-10-05
CN105392579A (zh) 2016-03-09
US20160158833A1 (en) 2016-06-09
KR20160018784A (ko) 2016-02-17
JP2015027689A (ja) 2015-02-12

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