USRE30380E - Mold for continuous casting of metal - Google Patents

Mold for continuous casting of metal Download PDF

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Publication number
USRE30380E
USRE30380E US05/726,940 US72694076A USRE30380E US RE30380 E USRE30380 E US RE30380E US 72694076 A US72694076 A US 72694076A US RE30380 E USRE30380 E US RE30380E
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US
United States
Prior art keywords
sleeve
explosive
mould
arbor
charge
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.)
Expired - Lifetime
Application number
US05/726,940
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English (en)
Inventor
Lorne R. Shrum
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Filing date
Publication date
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Classifications

    • 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
    • B22D11/057—Manufacturing or calibrating the moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/06—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure by shock waves
    • B21D26/08—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure by shock waves generated by explosives, e.g. chemical explosives
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49805—Shaping by direct application of fluent pressure
    • Y10T29/49806—Explosively shaping

Definitions

  • the present invention relates to a method of forming a tubular copper mould for the continuous casting of metals and more particularly to a method of forming a continuous casting mould of unitary construction by explosive forming techniques.
  • tubular moulds which may be curved or straight, are presently made from extruded tubing and have a cavity with a cross section usually of from 2 inch by 2 inch up to 6 inch by 6 inch and occasionally up to approximately 10 inch by 12 inch.
  • These moulds suffer from lack of accuracy, particularly when they are bent into a required curve, and whilst they are permitted to have in the order of 0.025 inch error when checked over their length with a profile template this applies only to an external curved surface and is not necessarily maintained over the inner surface.
  • a degree of spiral or twist has to be accepted.
  • segmental moulds may be formed from plate and mechanically assembled. Since it has not been practical to machine curved and tapered walls into mould cavities, each segment is machined separately and joints results between abutting segments when the mould is assembled. No matter how well the segments fit together, these joints deteriorate in use and result in gaps between segments, with defects being imparted to the cast product which are difficult to eliminate in subsequent rolling operations. The mould life is short and defective product is obtained. Segmental moulds can be reconditioned only a few times and by expensive remachining operations.
  • the object of the present invention is to provide tubular copper moulds for continuous casting which whilst in one piece may provide mould cavities of high accuracy and free of warp or twist, which moulds may be made of any desired size or cross-sectional profile, may easily be reformed, and may be made with small wall thicknesses. Accurate moulds of appropriate cross-sectional profile can last longer and provide substantial improvements in productivity and product quality as compared with those having a design-restricted or inaccurate profile, and/or a degree of warp or twist.
  • an arbor or core is formed which is externally machined to the required shape of the inner casting cavity of the particular mould being formed and having the same surface finish of the required mould, a sleeve having the same general shape of the finished mould is fitted loosely over the arbor, a cover plate and base plate are fitted to the top and bottom of the arbor-sleeve assembly, a charge of high explosive material is fitted around the sleeve to form an explosive jacketed assembly, the jacketed assembly is fully immersed in a liquid, the explosive is detonated from one end of the assembly to the other to insure uniform directional propagation of the detonation path and the mould so formed is pulled from the arbor. Any required external machining is carried out on the explosively formed mould to suit the finished mould for the continuous casting equipment in which it is to be used.
  • the enclosed drawing illustrates in a partially broken away perspective view a typical arbor and sleeve assembly with an explosive jacket applied thereto.
  • Arbor 1 is shown which preferably is of metal and is externally machined to close tolerances to be externally the exact shape and have the same surface finish as that desired for the internal cavity of the finished continuous casting mould being formed.
  • the material of the arbor is not critical provided that it will withstand the forces applied to it during forming of the mould without deformation and is sufficiently durable to be used repeatedly for as many times as may be required. For some applications an arbor of synthetic resin material will provide sufficient strength and durability.
  • a sleeve 2 which contains sufficient copper to form the finished mould and is of the same general shape as that mould is fitted loosely over the arbor 1.
  • the sleeve may be prepared in various ways, according to circumstances. It may be formed of a length of extruded tubing, or it may be cast, or more especially with larger sizes of sleeve, it may be fabricated from plate copper. Alternatively the sleeve may be a used mould which requires reforming to restore the original configuration of the mould cavity. The copper of the sleeve may be fully annealed, or work hardened to a greater or lesser degree, as is discussed further below.
  • Cover 3 and a base plate 4 are placed securely over the top and bottom of the arbor-sleeve assembly and, by use of gaskets 5, liquid medium in which the assembly is submerged is excluded from between the arbor 1 and the preform 2, where its presence would interfere with the forming process.
  • An exhaust port 6 may be provided through the cover 3 to enable the interior of the assembly to be evacuated. This is desirable if any appreciable air space exists between the sleeve and the arbor at any point since the resulting air pockets would otherwise interfere with the forming process.
  • High explosive material 7 which may be in sheet, strip, rod or cord form, is then fitted around the sleeve 2.
  • the explosive is applied in such a manner that, when detonated, it will provide a detonation path extending longitudinally of the sleeve from one end to the other. It may be in sheet, strip, rod or cord form, and in order to provide the desired detonation path, any strips, rods or cords will extend longitudinally of the sleeve, and will be distributed around the periphery of the sleeve so as to achieve a desired distribution of the forces applied to different portions of the periphery which will not necessarily be uniform.
  • the application of greater forming pressures will generally be required at the angles than upon intervening straight or curved portions of the periphery.
  • the forming pressure applied may be controlled not only by varying the type, distribution and amount of explosive applied, but also by standing off the explosive, or part of it, from the sleeve. This stand-off modifies the characteristics of the shock wave reaching the sleeve and reduces the forming pressure applied.
  • the necessary standoff may be achieved by interposing rubber sheet or strip of suitable thickness between the explosive and the sleeve, or by providing a frame or cage surrounding the sleeve and supporting the explosive at the required stand-off distance.
  • the amount of explosive used and the manner in which it is applied is related to the properties of the copper forming the sleeve, the form of the sleeve, and whether the sleeve is being formed for the first time or is a used mould being reformed.
  • the forming pressures required are in the order of 10 times the yield stress of the copper of the sleeve for new sleeves, and somewhat higher for used moulds being reformed.
  • the yield stress of fully annealed copper is about 9000 lb/sq.in. rising to about 40,000 lb/sq.in. for hardened copper.
  • the forming pressure utilized will also be dependent on the degree of work hardening of the copper desired during the forming process. With an initial hardness of 45 Brinell (500 Kg load) there is no difficulty in achieving a hardness of 75 Brinell (500 Kg load) on the internal surface of the mould in contact with the arbor when no stand-off is used to separate the explosive from the external face.
  • the external surface of the mould will be hardened to over 100 Brinell (500 Kg load).
  • a higher degree of hardening of the internal mould surface may be achieved if desired by prehardening this surface.
  • the type and quantity of explosive and the degree of stand-off used may be varied according to known techniques in the use of explosives so as to apply the required forming pressures to the sleeve when the explosive jacketed assembly is submerged in liquid and the explosive detonated.
  • Explosive which has a relatively high detonation velocity such as, for example one containing PETN (pentaerithritol-tetranitrate).
  • a shock wave must be generated of such magnitude as to move the sleeve into intimate contact with the arbor and achieve plastic flow of the inner surface of the sleeve in contact with the arbor.
  • the shock wave must travel at a much higher speed than the propagation velocity of sound through the liquid in which the assembly is immersed, which is about 1500 meters per second in the case of water.
  • An explosive sold by the DuPont Company under the trade mark “Primacord” is most useful in that it produces a shock wave having a velocity of about 6000 meters per second. This explosive is in cord form.
  • a suitable explosive in sheet or strip form is that sold by the DuPont Company under the designation "Detasheet" (Trade Mark) C.
  • the liquid explosive used to submerge the explosive jacketed assembly is advantageously water, and the explosive is detonated from one end of the assembly to the other to insure uniform directional propagation of the explosion. Detonation is carried out under a liquid to cause sufficient use of the explosive energy and to eliminate noise problems. Furthermore, detonation should be carried out in a pit located below floor or ground level, thereby readily containing the explosive forces and avoiding the necessity for continually replacing containers which are damaged by repeated detonations.
  • the detonation may be carried out in any liquid which will transmit the required forces to the preform and the explosive jacketed assembly must be covered with a great enough depth of liquid to insure proper disposition of the explosive forces.
  • Water is, of course, the most advantageous liquid to use because of its cheapness and the complete insignificance of any loss thereof. Generally, it is found that a coverage of in the order of two feet of water or more over the assembly is necessary for efficient disposition of the explosive energy.
  • the assembly is removed and the formed sleeve is drawn off the arbor 1 to provide a mould with an inner casting cavity having a shape exactly complementary to that of the arbor 1.
  • the mould may be machined externally as desired to suit the equipment with which it is to be used. Only enough material need be used to provide a mould wall thickness of between in the order of 3/8 inch to not more than about 2 inch, depending on the application, and most moulds are less than 3 feet long.
  • a rectangular sleeve of cast annealed copper was prepared having a wall thickness of 11/2 inches and a length of 28 inches so as to be a loose fit over a steel arbor of the same length and a cross-section of 9 inches by 10.5 inches. Gasketed end plates were applied to the ends of the assembly to seal off the interior of the assembly which was evacuated.
  • Four strips of "Detasheet” C explosive, having a weight of 2 grams/sq.in., and each .Badd..[.1,125.]..Baddend. .Iadd.1.125 .Iaddend.inches wide by 28 inches long were applied to the corners of the sleeve over a 0.125 inch stand-offs of sheet rubber.
  • Two 28 inch strands of 60 grains/foot "Primacord" explosive were applied to each side of the sleeve between the corners over stand-offs of 0.25 inch sheet rubber.
  • the assembly was submerged in a waterfilled pit so as to provide a two foot cover of water and the explosive charge, which totalled 5,560 grains, detonated from one end of the sleeve.
  • the assembly was taken out of the pit, the end plates removed, and the sleeve readily withdrawn from the arbor.
  • the internal surface of the mould formed by the sleeve was found to have assumed accurately the configuration and surface finish of the arbor.
  • the assembly was then submerged and the explosive detonated as in the previous example, the total explosive charge being 5,125 grains.
  • the cavity of the mould so formed was found to be an exact complement, as to configuration and finish, of the arbor utilized.
  • the present method provides a continuous casting mould which has in the mould cavity accuracies beyond that required for successful operation of the mould, there being an absence of any spiral or twist, thereby allowing for easy withdrawal of the cast metal therefrom. Because it is the external surface of the arbor which is machined it is practical to form any design of variable cross section which is faithfully reproduced in the casting cavity of the mould and there are no design limitations on the cross-sectional profiles which can be produced within the mould. Furthermore, there are absolutely no joints in the moulds formed by the method of the invention and spend moulds can be readily resized by the method of the invention and re-used.
  • the amount of raw material required for moulds is reduced substantially by the present method, a very important item to consider with respect to very large moulds where material savings of at least 60 to 80 percent may be achieved. Also costly machining of cooling water passages in large moulds and of the mould cavities is eliminated.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Continuous Casting (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Press Drives And Press Lines (AREA)
US05/726,940 1973-11-06 1976-09-27 Mold for continuous casting of metal Expired - Lifetime USRE30380E (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB51531/73 1973-11-06
GB5153173A GB1449868A (en) 1973-11-06 1973-11-06 Mould for continuous casting of metal

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
US515072A Reissue US3927546A (en) 1973-11-06 1974-10-15 Mold for continuous casting of metal

Publications (1)

Publication Number Publication Date
USRE30380E true USRE30380E (en) 1980-08-26

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US05/726,940 Expired - Lifetime USRE30380E (en) 1973-11-06 1976-09-27 Mold for continuous casting of metal

Country Status (4)

Country Link
US (1) USRE30380E (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html)
JP (3) JPS5851777B2 (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html)
CA (1) CA1012734A (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html)
GB (1) GB1449868A (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030106666A1 (en) * 2001-12-07 2003-06-12 Roland Hauri Method for the blasting calibration of a chill mold
US11628485B2 (en) 2021-05-14 2023-04-18 Battelle Savannah River Alliance, LLC. Tooling assembly and method for explosively forming features in a thin-walled cylinder

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ZA754574B (en) * 1974-07-29 1976-06-30 Concast Inc A method of forming the walls of continuous casting and chill
JPS61151784U (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html) * 1985-03-13 1986-09-19
DE102013114326A1 (de) * 2013-12-18 2015-06-18 Thyssenkrupp Steel Europe Ag Gießkokille zum Vergießen von Stahlschmelze

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2969758A (en) * 1961-01-31 Apparatus for contour forming
US3153848A (en) * 1962-07-09 1964-10-27 North American Aviation Inc Method for controlling shock forces
US3160952A (en) * 1962-03-26 1964-12-15 Aerojet General Co Method of explosively plating particles on a part
US3172199A (en) * 1962-09-19 1965-03-09 Schmidt William Method of hardening
US3364561A (en) * 1966-02-10 1968-01-23 Du Pont Explosive tube bonding
US3433039A (en) * 1966-02-24 1969-03-18 Aerojet General Co Method and apparatus of forming integral ribs on tubes

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2969758A (en) * 1961-01-31 Apparatus for contour forming
US3160952A (en) * 1962-03-26 1964-12-15 Aerojet General Co Method of explosively plating particles on a part
US3153848A (en) * 1962-07-09 1964-10-27 North American Aviation Inc Method for controlling shock forces
US3172199A (en) * 1962-09-19 1965-03-09 Schmidt William Method of hardening
US3364561A (en) * 1966-02-10 1968-01-23 Du Pont Explosive tube bonding
US3433039A (en) * 1966-02-24 1969-03-18 Aerojet General Co Method and apparatus of forming integral ribs on tubes

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030106666A1 (en) * 2001-12-07 2003-06-12 Roland Hauri Method for the blasting calibration of a chill mold
US6827127B2 (en) * 2001-12-07 2004-12-07 Km Europa Metal Ag Method for the blasting calibration of a chill mold
US11628485B2 (en) 2021-05-14 2023-04-18 Battelle Savannah River Alliance, LLC. Tooling assembly and method for explosively forming features in a thin-walled cylinder

Also Published As

Publication number Publication date
JPS6017624B2 (ja) 1985-05-04
JPS6040945B2 (ja) 1985-09-13
JPS5851777B2 (ja) 1983-11-18
JPS59130651A (ja) 1984-07-27
JPS50105512A (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html) 1975-08-20
CA1012734A (en) 1977-06-28
JPS59130650A (ja) 1984-07-27
GB1449868A (en) 1976-09-15

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