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The turret system at continuous casting machine is a part of the equipment that supports and rotates the ladles that contain the molten steel. The turret system allows the ladles to be switched between the melting furnace and the tundish, which is a container that feeds the molten steel into the mold. The turret system also enables the ladles to be tilted and adjusted to control the flow rate and temperature of the molten steel.
The turret system consists of several components, such as:
The cantilever arm: This is a long and sturdy beam that holds the ladles at both ends. The cantilever arm can rotate on a vertical axis and deflect on a horizontal axis, allowing the ladles to be moved and aligned with the tundish and the mold.
The bearings and seals: These are the parts that enable the smooth and stable movement of the cantilever arm and the ladles. The bearings and seals should have a high load capacity, a low friction coefficient, and a high resistance to heat, pressure, and contamination.
The drive and control system: This is the part that provides the power and commands for the rotation and deflection of the cantilever arm and the ladles. The drive and control system should have a high accuracy, a high reliability, and a high flexibility to adapt to different casting conditions and requirements.
The design and performance of the turret system are important for the quality and efficiency of the continuous casting process. A good turret system able to handle heavy and large ladles, operate at high temperatures and pressures, prevent leaks or blockages, reduce vibrations or shocks, and minimize maintenance and repair costs
Ladle is a large vessel that transports and pours the molten metal from the furnace to the tundish. It is equipped with a refractory lining and a nozzle to control the metal flow. The ladle can also be used to adjust the chemical composition and temperature of the metal by adding alloys or fluxes
Tundish is a broad, open container with one or more holes in the bottom. It is used to feed molten metal into the mold and to regulate the flow rate and temperature of the metal. The tundish also acts as a buffer and a cleaner for the metal, removing impurities and preventing air bubbles3
The design for oscillation table at continuous casting machine is another important factor that affects the quality and efficiency of the casting process. The oscillation table is the part that supports and moves the mold assembly up and down during the casting process. The design for oscillation table should consider the following aspects:
The structure and material of the oscillation table: The oscillation table should have a sturdy and rigid structure that can withstand the weight and force of the mold assembly and the cast product. The oscillation table should also have a durable and resistant material that can endure the high temperature and pressure of the casting process. Some examples of materials that are commonly used for oscillation tables are steel, cast iron, or aluminum alloy.
The drive and control system of the oscillation table: The oscillation table should have a reliable and precise drive and control system that can move the mold assembly according to the desired frequency, amplitude, and waveform. The drive system should also have a smooth and stable operation, avoiding vibrations and shocks that may damage the mold assembly or the cast product. Some examples of drive systems that are commonly used for oscillation tables are hydraulic, pneumatic, or electric.
The alignment and adjustment system of the oscillation table: The oscillation table should have an accurate and flexible alignment and adjustment system that can align and adjust the position and orientation of the mold assembly relative to the casting direction. The alignment and adjustment system should also have a simple and convenient operation, allowing the operators to change the settings for different products or conditions. Some examples of alignment and adjustment systems that are commonly used for oscillation tables are mechanical, optical, or laser.
The design for mold assembly at continuous casting machine is an important factor that affects the quality and efficiency of the casting process. The mold assembly consists of several components, such as the mold, the mold oscillation system, the mold cooling system, and the mold powder system. The design for mold assembly should consider the following aspects:
The shape and size of the mold: The mold is the part that forms the initial shape and cross-section of the cast product. The shape and size of the mold should match the desired product specifications and requirements. The mold should also have a suitable taper, which is the difference in width between the top and the bottom of the mold. The taper affects the friction and heat transfer between the mold and the cast product, and should be optimized to prevent defects such as bulging, cracking, or sticking.
The mold oscillation system: The mold oscillation system is the part that moves the mold up and down during the casting process. The mold oscillation system helps to break the contact between the mold and the cast product, reducing the friction and improving the surface quality. The mold oscillation system should have a proper frequency, amplitude, and waveform, which affect the solidification and deformation of the cast product. The mold oscillation system should also have a smooth and stable operation, avoiding vibrations and shocks that may damage the mold or the cast product.
The mold cooling system: The mold cooling system is the part that cools down the mold and the cast product during the casting process. The mold cooling system uses water or other fluids to circulate through channels or nozzles inside or outside the mold. The mold cooling system should have a sufficient cooling capacity and a uniform cooling distribution, which affect the temperature and solidification of the cast product. The mold cooling system should also have a reliable and safe operation, preventing leaks or blockages that may cause overheating or thermal shock.
The mold powder system: The mold powder system is the part that applies a layer of powder on top of the molten steel in the mold during the casting process. The mold powder system helps to protect the molten steel from oxidation and heat loss, lubricate the contact between the mold and the cast product, and absorb impurities and inclusions from the molten steel. The mold powder system should use a suitable type and amount of powder, which affect the viscosity, fluidity, and consumption of the powder. The mold powder system should also have a uniform and continuous application, avoiding gaps or excesses that may cause defects or slag entrapment.
The key figure for mold assembly at continuous casting machine is the mold taper. The mold taper is the difference in width between the top and the bottom of the mold, which affects the shape and quality of the cast product. The mold taper is usually expressed as a percentage or a ratio, such as 1.5% or 1:66. The mold taper is determined by several factors, such as the casting speed, the steel grade, the cooling rate, and the mold oscillation. The mold taper should be optimized to prevent defects such as bulging, cracking, or sticking of the cast product.
Withdrawal machine is a device that pulls the solidified strand of steel from the mold and guides it through the continuous casting process. It consists of rollers that grip the strand and move it at a controlled speed. The withdrawal machine also adjusts the strand thickness and shape according to the desired product specifications1
Dummy bar is a metal beam that is inserted into the mold to initiate the casting process. It serves as a support for the liquid steel until it solidifies enough to be self-supporting. The dummy bar is then detached from the strand and returned to the storage area2
The control room for continuous casting machines is a place where the operators and supervisors can monitor and control the casting process in real time. The control room should have the following features:
A large display screen that shows the live video feed of the casting machine and the product quality. The screen should also show the relevant data and parameters of the casting process, such as the speed, temperature, cooling rate, and chemical composition of the steel.
A computer system that runs the software and algorithms that control the casting machine and its components. The computer system should also have a user interface that allows the operators to input commands and adjust settings for the casting process.
A communication system that connects the control room with the other parts of the production plant, such as the melting furnace, the ladle metallurgy station, and the rolling mill. The communication system should also allow the operators to communicate with each other and with external parties, such as customers and suppliers.
A safety system that protects the control room from any hazards or emergencies that may occur during the casting process, such as fire, explosion, or power outage. The safety system should also have an alarm and an emergency stop button that can stop the casting machine in case of any malfunction or danger.
