KR100587988B1 - Method for manufacturing block for cooling jacket - Google Patents

Abstract

According to the present invention, there is provided a method of manufacturing a cooling jacket, comprising the steps of: casting a copper material into a cooling jacket block having a predetermined shape; Forging the molded cooling jacket block so as to bend it into a predetermined shape; Cutting the curved cooling jacket block so that the surface conforms to the design value; Forming a fluid passageway in the cut cooling jacket block, the method comprising: drilling two fluid passages parallel to each other in a first direction; passing the two fluid passageways in a second direction perpendicular to the first direction to interconnect the two fluid passageways; A fluid passage forming step of perforating one fluid passage; A screw having a threaded surface formed in a drill insertion hole formed in one side of the block to puncture the fluid passage in the second direction, and an outer end of the plug further penetrates inwardly than the one side of the block Performing a welding so that the gap between the welding space and the thread surface of the block corresponding to the thread of the plug can be filled with a welding material containing 65% of copper and 35% of silver; And checking the water pressure durability of the completed block and the coolant fluidity in the fluid passage.

Description

TECHNICAL FIELD [0001] The present invention relates to a method of manufacturing a cooling jacket block,

1 is a perspective view showing a cooling jacket block in a cast state according to the present invention.

2 is a perspective view showing a cooling jacket block in a forged state.

3 is a perspective view showing a cooling jacket block in a cut state.

Fig. 4 is a perspective view showing a cooling jacket block in a state in which the fluid passage is perforated. Fig.

5 is a perspective view showing a cooling jacket block in a finally completed state

6 is a cutaway perspective view of a part of a cooling jacket block in a state where the plug is engaged;
7 is a flowchart schematically showing a manufacturing process of a cooling jacket block according to the present invention.

The present invention relates to a method of manufacturing a block for a cooling jacket, and more particularly to a block for a cooling jacket in which a seal of a cooling water passage is ensured.

Since the melting furnace for dissolving a metallic material such as lead (Pb) is usually heated to a high temperature, the melting furnace is cooled to an appropriate temperature in order to prolong the lifetime of the furnace made of graphite. The outer circumferential surface of the melting furnace is surrounded by a plurality of cooling jacket blocks for cooling the melting furnace. The cooling jacket block is manufactured by processing a copper material having excellent thermal conductivity into a predetermined shape, and a cooling water passage through which cooling water can flow is formed inside the block. The cooling water circulating through the cooling water passage of the cooling jacket block serves as a cooling medium for cooling the melting furnace to an appropriate temperature.

There are two technically important points in the method of manufacturing the cooling jacket block. First, since the melting furnace in which the cooling jacket block is installed on the outer periphery has a cylindrical shape as a whole, the cooling jacket block must be machined so that at least one surface corresponds to the outer circumferential surface of the melting furnace. Therefore, the cooling jacket block should be made to have a predetermined shape by applying appropriate processing methods.

Next, the cooling water passage formed inside the cooling jacket block must seal the drill insertion port formed for drilling, and the stability of the seal must be ensured. That is, since the passage of the cooling water has a bent shape, holes other than the cooling water inlet and outlet formed for connecting the pipes must be drilled in order to insert the drill purely. The drill insertion port thus formed should be sealed afterwards, and the seal must be ensured so that the high-pressure cooling water flowing through the cooling water passage does not leak. If a seal with sufficient stability is not formed, high-pressure cooling water may leak and even if the seal is destroyed in any one block, it may have a negative effect on all the blocks making up the whole.

Conventionally, in the prior art, a welding method using a plug having a threaded surface is applied to seal the perforated hole. The threaded surface formed on the plug is coupled to the threaded surface formed on the block and the welding is used to form the seal by flowing the molten weld material between the threaded surface of the plug and the threaded surface of the block. However, even if the welding electrode material is heated and melted in the prior art, there is a problem that the flowability of the welding material itself is insufficient so that it can not be sufficiently injected between the slant surfaces. For example, a plug coupled to a drill insertion port of a cooling jacket block typically has five to six threads formed. After performing the welding in a conventional manner, the block is cut and observed, It can be seen that only the portion corresponding to -4 flows, and the welding material does not flow at deeper portions. Therefore, there has been a problem that the stability and reliability of the seal are not guaranteed in the prior art.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method of manufacturing an improved cooling jacket block.

Another object of the present invention is to provide a method of manufacturing a cooling jacket block in which the stability of the seal and the reliability are ensured.

In order to achieve the above object, according to the present invention, there is provided a method of manufacturing a cooling jacket, comprising the steps of: casting a copper material into a cooling jacket block having a predetermined shape;

Forging the molded cooling jacket block so as to bend it into a predetermined shape;

Cutting the curved cooling jacket block so that the surface conforms to the design value;

Forming a fluid passageway in the cut cooling jacket block, the method comprising: drilling two fluid passages parallel to each other in a first direction; passing the two fluid passageways in a second direction perpendicular to the first direction to interconnect the two fluid passageways; A fluid passage forming step of perforating one fluid passage;

A screw having a threaded surface formed in a drill insertion hole formed in one side of the block to puncture the fluid passage in the second direction, and an outer end of the plug further penetrates inwardly than the one side of the block Performing a welding so that the gap between the welding space and the thread surface of the block corresponding to the thread of the plug can be filled with a welding material containing 65% of copper and 35% of silver;

Inspecting the hydraulic durability of the completed block, and the coolant fluidity in the fluid passage, are provided.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will now be described in detail with reference to an embodiment of the present invention shown in the accompanying drawings.

1 to 5 schematically show a step-by-step process for manufacturing a cooling jacket block according to the present invention.

Referring to FIG. 1, the cooling jacket block has a shape of a rectangular parallelepiped block 11 by casting a material such as copper. The melting temperature applied to the casting is 1,160 deg. C to 1,180 deg. C, and after heating for 8 to 10 hours at a time, the casting mold is poured into a mold having a predetermined shape to produce the block 11 as shown in Fig. It is preferable that the block 11 made by casting has a copper purity of 99.9% or more, and the conductivity is measured. The conductivity is preferably 80% or more.

2 is obtained by deforming the block 11 of FIG. 1 into a block 12 having a generally curved shape by forging. The forging process is flattened first and second at temperatures between 750 and 800 degrees centigrade. Performing the forging process is to improve the stiffness of the block 12 while simultaneously deforming the shape of the block 12 close to the shape of the final finished product.

3 shows a block 13 that has been completed through a finishing process for cutting the block 12 of FIG. 2 into a predetermined shape. A block 12 shaped like a curved shape by forging is removed from a part of the upper plane (indicated by 14 and 15 in Fig. 3) as shown in Fig. 3, and the entire surface of the block is surface-processed by milling or the like. Through the finishing process, the outer contour dimension of the block 13 coincides with the design value.

4 shows forming the fluid passage 18 in the block 13 of FIG. As shown in the figure, in the block 13, two fluid passages are formed parallel to each other in the vertical direction, and one fluid passageway is formed in the horizontal direction. The two vertically formed fluid passages are connected to each other by a single horizontally formed fluid passage, thereby forming a fluid passage 18 having a "C" shape. The vertical and horizontal passages may be formed by a drill, such as a gun drill.

In order to perforate the fluid passage horizontally in the block 13, a drill insertion port 19 should be formed on the side surface of the block 13. The drill insertion port 19 is closed by welding with the plug 20 after the horizontal fluid passage is completed. A screw 20a is formed at the end of the plug 20 and the screw 20a of the plug 20 is fixed by being engaged with a corresponding screw surface formed in the drill insertion port 19 of the block 13. [ It is preferable that the screw surface 20a is normally formed with 5 to 6 threads.

6 is a cutaway perspective view showing welding of the drill insertion port of the block into which the plug is inserted.

Referring to the drawings, when the plug 20 is coupled into the block 13, the plane of the outer end of the plug 20 is located on the side of the block 13 (Fig. 5) And the welding space 62 is formed at the end of the plug 20 accordingly. The welding space 62 is a space filled with the welding material dissolved in the welding rod 61 and the side surface 13 of the block 13 becomes an overall smooth surface after welding is completed. The welding material dissolved in the welding rod 61 not only fills the welding space 62 but also flows into the minute gap formed between the thread face 20a of the plug 20 and the thread face of the corresponding block 13, do.

In order for the welding material to flow between the plug 20 and the screw surface formed in the block 13, sufficient fluidity must be secured when the welding electrode is dissolved. In addition, the seal must be ensured when flowing the high-pressure cooling water into the fluid passage 18 in the completed block after the welding is finished, and the heat transmitted from the high-temperature melting furnace must also be heat-resistant. For this purpose, it is preferable that the electrode includes copper (Cu) of 65% and silver (Ag) of 35%. By including 35% of silver in the electrode, the flowability of the dissolved weld material can be improved, and accordingly, the gaps between 5 to 6 formed threads can be filled with the welding material and welded. Improving the flowability of the welding material by including silver and copper in the material of the electrode as described above constitutes a main feature of the present invention.

Silver material is less likely to be melted when the high temperature of the melting furnace is transferred because the melting point of the silver material is lower than that of copper. In reality, however, the range of temperatures at which the melting furnace is operated normally is much lower than the melting point of the silver material. Therefore, when the welding material is not filled between the threads 20a of the plug 20, rather than the possibility that the seal is broken at the welded portion of the end portion of the plug 20 due to the high temperature of the melting furnace, It is understandable that it is more likely to be destroyed.

In the operation of welding the plug 20, first, the peripheral portion where the plug 20 is inserted in the block 13 is preheated to about 900 degrees Celsius by using a torch or the like, and then the welding rod is inserted into the welding space Tig welding at about 800 degrees Celsius.

Fig. 5 shows the finally completed cooling jacket block. In the cooling jacket block 50, the welded portion 51 becomes a smooth surface by performing surface processing using milling or the like after the welding is completed.

The cooling jacket block finally manufactured is subjected to a predetermined inspection process. Inspection items include durability tests for water pressure and fluidity testing of fluid passages.

In Fig. 7, the process of manufacturing the above-described cooling jacket block is shown in a schematic flow chart.

Referring to the drawing, first a material such as copper is melted in a block casting step 71 and cast into a mold to cast the block 11 and then hot forging the block 11 in a block forging step 72, Thereby forming a block 12 in a shape of a cylinder. Next, in the finishing step (73), each surface of the block is processed so as to conform to the design value. Next, a fluid passage 18 is formed by using a perforated drill such as a gun drill. Next, in the plugging and welding step 75, the plug 20 is screwed to the threaded surface formed on the inner side of the drill insertion port 19 and the plug 20 and the block The welding space 62 formed between the threaded surfaces of the plug 12 and the end of the plug 20 is filled with the welding material. After the welding is finished, the inspection is performed in accordance with the inspection items determined in the inspection step (76), thereby completing the fabrication of the cooling jacket block.

The cooling jacket block according to the present invention is characterized in that not only the overall mechanical properties of the block itself are improved by casting and forging processes in sequence, but also by using a welding material which ensures fluidity at the time of melting and ensures welding at the time of solidification, The seal of the fluid passage can be ensured by closing the drill insertion port. Therefore, the cooling jacket block according to the present invention can secure stability and reliability.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. It will be possible. Accordingly, the true scope of the invention should be determined by the appended claims.

Claims (1)

Casting a copper material into a cooling jacket block of a predetermined shape; Forging the molded cooling jacket block so as to bend it into a predetermined shape; Cutting the curved cooling jacket block so that the surface conforms to the design value; Forming a fluid passageway in the cut cooling jacket block, the method comprising: drilling two fluid passages parallel to each other in a first direction; passing the two fluid passageways in a second direction perpendicular to the first direction to interconnect the two fluid passageways; A fluid passage forming step of perforating one fluid passage; Formed by forming a threaded plug on a drill insertion port formed in one side of the block to puncture the fluid passage in the second direction and further forming an outer end of the plug further inward than one side of the block Performing a welding so that the gap between the welding space and the thread surface of the block corresponding to the thread of the plug can be filled with a welding material containing 65% of copper and 35% of silver; Inspecting the hydraulic durability of the completed block, and the coolant fluidity in the fluid passage.

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