RU2081724C1 - Apparatus for metal blanks continuous casting - Google Patents

Abstract

FIELD: method of discrete blanks continuous casting. SUBSTANCE: two-converter casting facility of continuous action has the shaping inserts like separators, that are used by upper conveyer to shape metal as discrete segments. Shaping inserts of different size and form are used. EFFECT: improved design. 6 cl

Description

 The present invention relates to equipment and technological processes for casting discrete solid molds from a fluid, plastic or molten material. It is characteristic that the invention provides continuous casting of discrete molds using a static extrusion molding machine or, preferably, a moving extrusion injection molding machine, where, for example, molds are formed between spaced parts of paired endless flexible casting conveyors moving continuously with opposite surfaces of the injection metal.

 Although the principles of the invention can be used to cast any flowable, ductile, molten material, such as plastics, the invention will be described in terms of continuously casting molten metal into discrete and various forms, such as ingots, anodes, wire strips or castings .

 Discrete metal molds are mainly poured in individual molds using an intermittent stream of molten metal. Many molds are filled sequentially and the flow of metal in the required quantity for each mold is controlled manually by the operator or automatically. Continuous casting is used in ferrous and non-ferrous metallurgy and, in addition, serves to reduce the cost of production and improve its quality. The two main systems, known as static and moving press methods, are used in continuous casting, such as billets or continuous strips. In a static molding machine, the mold walls are motionless, while the injection product, on the contrary, moves and freezes inside them. Moving molding machines include a conveyor, chain, drum, wheel, or other surfaces that move at approximately the same speed as the solidifying metal.

 Continuous casting of metal on moving molding machines having at least one moving conveyor and a corresponding fixed or moving surface, which together form a mold of two opposing surfaces in which the cast material solidifies, is described in detail in the following US patents, combined here for Reference: 2631343, 2904860, 3036348, 3123873, 3123874, 3167830, 3533463, 3878883, 3921697, 3937270, 3937274, 3949805, 3955615, 4002197 and 4854371.

 In the operation of an injection plant with two moving conveyors that form a mold, a continuous stream of molten metal enters through the inlet of the installation into a cavity formed by a pair of movable flexible injection conveyors located mainly one above the other, forming the walls of the molds, and exits from the other end of the cavity ( installation outlet) in the form of a strip or metal ingot. The strip or ingot is subsequently fed to another installation for machining, cutting or welding, which change the dimensions of its cross section. For example, a double conveyor injection molding apparatus of the type described is used to turn molten copper into an approximately rectangular block, which is then sent to a roller installation having a series of roller steps for turning a rectangular block into a round bar. Typically, the rod is ultimately drawn into a wire of different sizes.

 In a previous attempt to produce objects of a certain shape continuously, the injection molding machine with a double conveyor was modified by reducing the jumpers of the mold at a certain distance, ensuring that the casting material acquires the shape of the anode, that is, a flat rectangular shape having supporting handles. After casting, however, the injection part must be cut to form separate anode shapes.

 Another continuous injection method with moving molds uses an injection wheel having a peripheral groove around it. A portion of the peripheral trough is closed by an endless conveyor, forming a mold into which molten metal is poured to solidify into the cast metal and unloaded from it. Such a construction can be seen in US Pat. Nos. 3,279,000 and 3,469,620, whose patents are hereby incorporated by reference.

 Continuous casting using static molds can be found in US Pat. Nos. 2,938,251, 2,946,100, 3,066,364, 3,089,209, 3,098,269, and 3,115,686, whose patents are incorporated herein by reference.

 Essentially, the molten metal continuously enters the mold, freezes and the frozen article is continuously withdrawn from the mold. Typically, the mold is in an upright position, molten metal flows into the upper part of the mold.

 While the injection molding machines described here are very successful and widely used in industry, there is a need for the existence of types of continuous injection molding machines that produce discrete shapes.

 The aim of the invention is the provision of installation and method for continuous casting of such discrete forms.

 The present invention is directed to the improvement of continuous injection molding machines and includes an apparatus and method for using a continuous injection molding apparatus for casting discrete forms such as wire strips, ingots, billets, briquettes, strips and injection molds from a stream of molten material. Although the invention can be used in any type of continuous casting machine, for convenience it will be described in detail for casting lead ingots using a double conveyor molding machine in which a pair of moving conveyors forms a moving mold for molten metal.

 The proposed installation can serve for any fluid, ductile or molten material, such as plastics, ferrous and non-ferrous metals, including without limiting steel, iron, copper, cast iron, bismuth, aluminum. The invention is particularly useful for the continuous casting of brittle or brittle materials that cannot be rolled normally, rolled by rolling, not stretching, not drilling in the solid state.

 The installation includes a continuous injection mechanism having the first means for determining the shape, the aforementioned first device, including a fixed or moving surface, depending on the form used, a second device for supplying a constant flow of molten material into the mold, one or more molding elements that form discrete chambers in the form and mold molten material in the form of injection material in the form of discrete segments, devices for hardening and will divide devices for separating discrete segments in discrete forms of cast material. For a two-conveyor injection installation, the moving surface is flat, while for a wheeled installation, the moving surface is a curve. In stationary forms, the form is stationary relative to the molten material. In stationary forms, reciprocating or vibrating motion during casting is usually used.

 The invention is illustrated by drawings.

 In Fig.1 shows a schematic installation for continuous casting.

 Figure 2 is a partial side view.

 Figure 3 is a top view of the lower conveyor showing the shape of the ingot.

 Figure 4 is a side view of the lower conveyor showing the shape of the ingot.

 In the injection plant 10, molten metal 11 flows from a pouring tank or bucket (not shown) into the cell 12. From the cell 12, the molten metal 11 is fed into the inlet 13, is formed between the parallel surfaces of the upper and lower endless flexible casting conveyors 14 and 15. The container formed between the conveyors 14 and 15 and the walls of the webs 16 can be defined as a casting space 17 in which molten metal is cast into conceived shapes and solidifies. Injection conveyors are preferably made of steel or other alloys that provide rigidity and resistance against abrasion and physical damage, as well as resistance to temperature extremes, thermal stress differences carried during casting.

 Injection conveyors 14 and 15 are supported and controlled by upper and lower holders, designated 18 and 19 relative. Both holders are mounted on an installation case (not shown). Each holder includes two main rolls that support, drive and guide injection conveyors. These rolls include upper and lower input rolls 20 and 21 and upper and lower output rolls 22 and 23 relative.

 A flexible, endless lateral support bridge 16 is located on each side of the injection conveyors to define the lateral edges of the injection space and to enclose molten metal. The side jumpers 16 are guided to the input end of the injection machine 10 with crescent-shaped devices 24 that are mounted on the lower holder 19.

 During the injection process, both injection conveyors 14 and 15 are driven with the same linear speed by the drive mechanism, and the upper and lower holders are mainly inclined towards the downward direction, in the downstream direction, so that the injection space 17 between the injection conveyors tilted. Such an inclination towards the descent contributes to the flow of molten metal into the casting space.

 After casting hardens and leaves the installation, as described in paragraph 25, secondary cooling devices 26 can be applied until the casting has completely solidified and / or cooled. The use of such a technique is called “secondary cooling” and is used in the manufacture of high-speed casting methods. The use of secondary cooling also contributes to the movement of the molding devices 27 from the cast metal by means of a heat stroke mechanism resulting from different expansion coefficients of the molding devices and excellent metal. The large difference between the coefficients determines a greater thermal shock and a large separation effect. Primary cooling devices (not shown) are typically made using a fluid cooler moving at a high speed, passing from the opposite side of the conveyors 14 and 15, which form a mold.

 The installation of the present invention uses forming inserts 27 on injection conveyors to provide a discrete shape on the mold and in the injection space 17 of the installation. The forming inserts 27 are mainly attached to the upper injection conveyor 14 and can vary in shape and location to determine the intended shape in the injection molding space 17 of the installation. Typical designs for forming liners are described below.

 In the presented embodiment of the invention, the auxiliary holder 28 and the conveyor 29 are used to allow the forming inserts 27 to separate from the conveyor 14, to be assembled according to the timer 30 and located on the conveyor 14 according to a predetermined desired distance. Through the use of this separation system, the weight (and size) of the discrete injection molds during the casting process can be varied by an adjustment timer 30. The holder 28 can use two rolls 31 and 32, as indicated.

 Discrete forms 33 are removed from the injection plant and transported to the desired location.

 The injection plant 10 and the cuvette (bath) 12 are generally of the “open reservoir” type with a specially modified bath outlet in order to allow the molding inserts 27 to enter the injection space 17. A portion of the molten metal in the inlet 13 of the injection installation is mainly , fills it so that the forming inserts 27 are in contact with the molten metal 11 in the inlet 13.

 The end of the bath is typically made of graphite or other soft, melting material that facilitates the casting and lubrication of the lower conveyor 15. The movement of the proposed mechanism is shown in FIG. 2. Since metal, conveyor and forming tools are found at approximately the same place, any gas or steam behind the forming inserts 27 may be released into the open atmosphere and not cause bubbles to form behind the forming tools in metal casting. The lintels of the molds 16, as a rule, have a slightly conical shape from the inner surface (more at the base), to prevent the turning of the forming devices or their movement inside the mold.

 When metal passes through an injection plant, the same process as in standard injection plants occurs. However, the casting speed can typically be increased or decreased through the use of forming liners 27, which act as heat absorbers or insulators, depending on the material used to make the molding devices.

 In the embodiment shown, the forming inserts 27 are movably attached, for example, magnetically, to the conveyors 14 and 29. In operation, the forming devices will be located on the conveyor 14 and, when the conveyor is rotated, the desired injection mold is formed. After hardening, discrete casting should be separated from the continuous casting strip with forming inserts that have become magnetically attached and transferred to conveyor 29. The forming inserts 27 should then be moved to timer 30, where they will be placed in a straight line and released again onto conveyor 14 in the desired location.

 The mechanism for separating discrete castings from the casting strip made in the casting installation can be conveniently applied in paragraph 34. For example, a bending movement can be used with respect to casting with forming inserts 27 removed from the conveyor 29 and transferred to the casting conveyor 14, as described here above.

 The design of the forming liners 27 can be completely varied. As shown in FIG. 3, the Y-shaped forming liners 27 produce the shape of the ingot 33. Also FIG. 4 shows inverted T-shaped forming inserts 127, which also produce mold ingots 33. If holes, cavities, indentations, brand names or other marks are required, they can be made using the corresponding forming inserts.

 Molding inserts 27 may be made of a variety of materials. As for the magnetic separators, the stronger the magnetic force of the forming inserts, the lower the internal slope or arrangement in one straight line is required to block the forming inserts in the mold space. In some cases, it may be necessary to make the molding inserts partially or completely from sand or refractory material, or metal balls, as a substitute for drilled or cast complex holes and molds in castings, or as a separator.

 The removal of forming inserts 27 from the conveyor 14 and / or casting can be facilitated by the use of forming inserts that are expendable (such as wood) or disposable. Another concept is to use thin flexible forming inserts with walls containing a substance, such as water, that expand upon contact with molten metal (due to the formation of steam or water vapor in the forming devices) and which are compressed by cooling. Thus, when the forming inserts come into contact with the molten metal 11, the forming inserts expand and molding is molded with the expanded forming inserts. After solidification and cooling, the forming inserts are compressed, making it easier to deflect. Thin-sized steel stainless forming liners can be conveniently used for casting lead ingots.

 In injection plants using an injection wheel, the forming inserts 27 may be located on a wheel or conveyor to indicate the discrete forms required on a mold formed by a peripheral groove on the injection wheel and an endless conveyor, as discussed above. For continuous casting using a fixed mold, the forming inserts 27 can be inserted into the mold cavity at planned distances to allow separation in the molten metal (division in discrete forms). Refractory balls can be used as balls inserted into the mold cavity, forming compartments in the molten metal that is cast. The cast metal can then be easily divided into discrete forms after solidification.

Claims (6)

 1. Installation for continuous casting of metal billets, containing a mold having two flat surfaces, jointly moved along the longitudinal axis, and transverse lateral jumpers forming the mold space of the mold, means for supplying a continuous stream of molten metal into the mold space, a cooling device to provide solidification of the molten metal, characterized in that it is equipped with forming inserts installed in the required sequence on at least one of flat surfaces for forming the molten metal into discrete segments, and means for separating the solidified metal into discrete castings.  2. Installation according to claim 1, characterized in that the forming inserts are attached to the upper flat surface.  3. Installation according to claim 2, characterized in that it is equipped with a means for separating the forming inserts from the upper surface of the hardened metal after it leaves the mold space.  4. Installation according to claim 3, characterized in that the means for separating the forming inserts is made in the form of a drum with a tape having magnetic properties.  5. Installation according to claim 4, characterized in that it is provided with means for storing the forming inserts after separating them from the casting and installing them on an upper flat surface.  6. Installation according to any one of paragraphs. 1 to 5, characterized in that the two movable flat surfaces are tapes.

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