Negative compensation forming process for producing zirconia-inlaid slide plate brick by full-automatic hydraulic press

Abstract

The application discloses a negative compensation forming process for producing zircon-inlaid slide plate bricks by using a full-automatic hydraulic machine, which comprises the following steps: step S1, preparing mud according to a proportion; step S2, mixing the mud in step S1 by using a high-speed mixer until the mud is uniformly mixed, and then detecting the mixed mud; step S3, hoisting the detected mud to a press machine bin, setting parameters of the hydraulic machine in real time according to a compression ratio of the mud detection, and starting to press the bricks by using a negative compensation method; and step S4, demoulding, measuring the size of the first formed brick, weighing the first formed brick, and appropriately trimming the first formed brick until the first formed brick meets internal control requirements, and then normally pressing the bricks according to a full-automatic mode. The application improves the density uniformity of the products, improves the product quality stability and the production efficiency, and reduces the product size deviation and the warping deformation by adopting a reverse compensation correction according to thickness deviation data of the products during a period.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of metallurgical refractory materials, in particular to a negative compensation forming process for producing zircon-inlaid slide plate bricks by a full-automatic hydraulic machine. BACKGROUND

[0002] The existing zircon-inlaid ring (plate) slide plate is mainly manually pressed by a friction press, and the forming indexes are relatively uniform by manually rolling and tamping the material and spring platform, but the skill requirement is high, the labor intensity of manual operation is large, the efficiency is extremely low, and the forming quality cannot be effectively guaranteed. The use of a full-automatic hydraulic machine to form high-life slide plate bricks will become a development trend in the industry. The hydraulic machine forming flat slide plate has no technical obstacles, and the production efficiency can be improved by several times. However, there is still little practice in the hydraulic machine forming composite slide plate and zircon-inlaid slide plate.

[0003] For example, the invention application with publication number CN111098542A discloses a full-automatic composite material one-time forming slide plate hydraulic machine, which sets composite hoppers and base hoppers through a rack, forms a cavity by falling a lower mold core, completes base material filling, fills composite material in the mold cavity by a composite material distributor after the base material is filled, and finally forms by pressing down the upper mold core after multiple exhausts. For example, the invention application with publication number CN202010289613.7 discloses a cast forming slide plate brick. The sinter-free slide plate brick not only reduces energy consumption and is environmentally friendly, but also greatly improves the work efficiency.

[0004] In the above-mentioned prior art, the full-automatic composite slide plate one-time forming process only realizes the function of layer composite forming slide plate, but the feeding is complex, only suitable for flat slide plate, and cannot compensate for different parts of the slide plate. Especially for the hydraulic machine forming zircon-inlaid plate slide plate or high sub-port slide plate, one-time forming is easy to cause the edge band to be too loose, the forming quality fluctuates obviously, and the relative thickness deviation is also difficult to control. Although the cast slide plate has a simple forming process, the high-temperature suitability of the slide plate is poor, the service life is low, and it cannot be widely used. SUMMARY

[0005] To solve the problems mentioned in the background art, the purpose of the present application is to provide a negative compensation forming process for producing zircon-inlaid slide plate bricks by a full-automatic hydraulic machine. Based on the relative movement of the split mold driven by the new full-automatic hydraulic machine, the product quality uniformity is improved by setting the mud accumulation height of the zircon-inlaid slide plate at different positions according to the mud compression ratio to complete the forming compensation setting at different positions. Secondly, the product thickness deviation data is obtained by size measurement, and further reverse compensation correction is made to reduce the size deviation and warping deformation of the slide plate. At the same time, different forming direction modes can be changed to improve the production efficiency and avoid defects at different forming positions.

[0006] The purpose of the present application can be achieved by the following technical solutions:

[0007] A negative compensation forming process for producing zircon-inlaid slide plate bricks by a full-automatic hydraulic press, comprising the following steps:

[0008] Step S1: preparing the mud according to the proportion, the weight ratio of the mud being: component A 40-80%, component B 0-35%, alumina micro powder 5-15%, antioxidant 3-8%, carbon material 1-8%, and phenolic resin 3-5%;

[0009] Step S2: mixing the mud in step S1 by a high-speed mixer, and then detecting the mixed mud, and confirming that the water content of the mud is in the range of 0.9-1.2% and the compression ratio of the mud is in the range of 1.5-1.7 before forming;

[0010] Step S3: hoisting the detected mud to the press bin, setting the parameters of the hydraulic press in real time according to the compression ratio of the mud, and starting to press the bricks by using the negative compensation method, and controlling the forming pressure, the cloth height, the forming thickness and the thickness difference during the forming;

[0011] Step S4: demolding, measuring the size and weight of the first formed brick, and appropriately trimming until the internal control requirements are met, and then normally pressing according to the full-automatic mode.

[0012] Further preferably, component A is tabular alumina or fused alumina, component B is fused zirconia mullite or fused zirconia alumina, and the antioxidant is mixed from one or more of metal Al, Si, B4C and BN.

[0013] Further preferably, in the mixed mud of step S2, the material with a particle size greater than 2 mm accounts for 10-15%, the material with a particle size of 2-0.088 mm accounts for 25-60%, the material with a particle size of 0.088-0.04 mm accounts for 10-20%, and the material with a particle size less than 0.04 mm accounts for 10-20%.

[0014] Further preferably, the automatic negative compensation method in step 3 is specifically as follows:

[0015] After the first sample is formed, the thickness deviation and the amount of distortion at different positions of the slide plate sample obtained by the first forming are determined, and a preliminary reverse compensation is made according to the deviation amount. If the reverse compensation effect is not satisfactory after the second forming is confirmed by measurement, the above operation is repeated until the thickness deviation meets the internal control requirements.

[0016] Further preferably, the reverse compensation is specifically as follows: the negative compensation height at different positions is calculated according to the measured thickness deviation amount by a compensation calculation formula, and then the cloth height of the mud at different ring belt sections is adjusted by adjusting the ring belt height at different positions of the slide plate mold cavity.

[0017] Further preferably, the compensation calculation formula is as follows:

[0018] H1=H2xr p x a,

[0019] Wherein: H1 is the negative compensation height of the mud; H2 is the thickness of the formed brick; r p is the mud detection compression ratio; a is the correction coefficient, which is set according to the volume ratio of the compensation amount of the mud at different positions to the volume after forming.

[0020] The beneficial effects of the present application are:

[0021] The present application improves the density uniformity of the product, improves the product quality stability and production efficiency by negative compensation. According to the thickness deviation data of the product during the period, reverse compensation correction is taken to reduce the product size deviation and warping deformation. At the same time, by changing the forming method in different directions, the production efficiency and quality can be further improved, and the defects in different forming positions can be targetedly avoided. BRIEF DESCRIPTION OF DRAWINGS

[0022] The present application will be further described below in combination with the drawings.

[0023] Figure 1 is a schematic diagram of the area structure where the warping deformation of the existing technology zircon inlaid sliding plate brick may occur

[0024] Figure 2 is a negative compensation forming schematic diagram of the zircon inlaid sliding plate brick of the present application;

[0025] Figure 3 is a zircon inlaid sliding plate forming schematic diagram of another embodiment of the present application;

[0026] Figure 4 is a zircon ring inlaid sliding plate forming schematic diagram of another embodiment of the present application;

[0027] Figure 5 is a negative compensation forming schematic diagram of the lateral forming zircon inlaid sliding plate of the present application.

[0028] In the drawings:

[0029] 1 - mandrel, 2 - mud, 3 - mold frame, 4 - outer ring, 5 - middle ring, 6 - inner ring, 7 - bottom plate, 8 - edge ring, 9 - pressing plate, 10 - pressing plate boss, 11 - green brick, 12 - bottom plate zircon plate, 13 - bottom plate zircon ring, 14 - feeding hole. DETAILED DESCRIPTION

[0030] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] In the description of this invention, it should be understood that the terms "opening", "upper", "lower", "thickness", "top", "middle", "length", "inner", "around", etc., which indicate orientation or positional relationship, are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the components or elements referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting this invention.

[0032] This invention discloses a negative compensation molding die for zircon-embedded sliding plate bricks, comprising several relatively movable split mold units, and a drive mechanism for driving the mold movement.

[0033] The split mold unit includes a ring mold module that can move up and down. The center position is a circular mandrel and an elliptical base plate. The outer ring molds may include a mandrel 1, a mold frame 3, an outer ring 4, a middle ring 5, an inner ring 6, a base plate 7, and a side ring 8. The mandrel 1 can move synchronously with the mold frame 3. The height of the inner ring 4, the middle ring 5, the outer ring 6, and the side ring 8 can be adjusted according to the height of the zirconium plate casting hole steps. Adjusting the height difference can form single or double step slides of different heights. The overall density can be adjusted and optimized by the material distribution height, which is calculated by the clay compression ratio.

[0034] The actuator includes a hydraulic cylinder that can move up and down and a connecting rod that moves synchronously at multiple points, which can realize the relative height adjustment of different parts of different ring molds.

[0035] like Figure 1 As shown, Figure 1 This is a schematic diagram of the area where warping deformation may occur in the current product. Location A is the location where warping deformation is likely to occur.

[0036] like Figure 2 The negative compensation molding die of the above-mentioned zircon-embedded sliding plate brick is used for pressing and molding. Before molding (2a), a compensation negative area is set above the middle ring 5 and the side ring 8. The pressure plate 9 and the pressure plate boss 10 press the clay down to form the zircon-embedded sliding plate brick. After molding (2b), the reverse compensation area of ​​the brick blank 11 can obtain a higher density.

[0037] like Figure 3 As shown, as another embodiment of the present invention, the molding method is relatively... Figure 1To simplify, the annular mold comprises a pressing plate 9, a mandrel 1, a mold frame 3, an outer ring 4, a bottom plate 7, and a bottom plate zirconium plate 12, and a negative compensation area is arranged above the bottom plate zirconium plate 12 before forming (3a), and a reverse compensation area of the green brick 11 after forming (3b) can obtain higher density.

[0038] As shown in Figure 4 As another embodiment of the application, the annular mold comprises a pressing plate 9, a mandrel 1, a mold frame 3, an outer ring 4, a bottom plate 7, and a bottom plate zirconium ring 13, and a negative compensation area is arranged above the bottom plate zirconium plate 13 before forming (4a), and a reverse compensation area of the green brick 11 after forming (4b) can obtain higher density.

[0039] As shown in Figure 5 As another embodiment of the application, a lateral forming zirconium plate sliding plate can be used to directly form a non-casting hole (5a) or a sliding plate with different casting hole heights (5b), and a feeding hole 14 is arranged on the side wall of the mold frame 3 to facilitate rapid feeding, and the mud is more easily filled in the entire cavity by applying positive pressure.

[0040] The application also discloses a negative compensation forming process of the full-automatic hydraulic machine for producing the zirconium sliding plate brick.

[0041] Step S1: Prepare mud in proportion, and the weight ratio of the mud is 40-80% of tabular corundum or fused corundum, 0-35% of fused zirconium mullite or fused zirconium corundum, 5-15% of alumina powder, 3-8% of an antioxidant, 1-8% of a carbon material, and 3-5% of phenolic resin;

[0042] Step S2: The mud in step S1 is mixed by a high-speed mixer, and then the mixed mud is detected, and the water content of the mud is confirmed to be 0.9-1.2% before forming, and the compression ratio of the mud is confirmed to be 1.5-1.7;

[0043] Step S3: The mud after detection is hoisted to a pressing machine bin, the parameters of the hydraulic machine are set in real time according to the compression ratio of the mud, and the negative compensation method is used to start pressing the brick, and the forming pressure, the feeding height, the forming thickness and the thickness difference need to be controlled during forming;

[0044] Step S4: Demoulding, size measurement, single weight measurement and appropriate trimming are performed on the first formed green brick, and then the green brick is normally pressed according to the full-automatic mode after the internal control requirements are met.

[0045] The antioxidant is mixed by one or more of metal Al, Si, B4C and BN.

[0046] The material with a particle size greater than 2 mm accounts for 10-15% in the mixed mud, the material with a particle size of 2-0.088 mm accounts for 45-60%, the material with a particle size of 0.088-0.04 mm accounts for 10-20%, and the material with a particle size less than 0.04 mm accounts for 10-20%.

[0047] The automatic negative compensation method in step 3 is specifically:

[0048] After the first sample is formed, the thickness deviation and distortion amount at different positions of the skateboard sample obtained by the first forming are determined, and preliminary reverse compensation is made according to the deviation amount. If the reverse compensation effect is not satisfactory after the second forming is confirmed by measurement, the above operation is repeated until the thickness deviation meets the internal control requirements.

[0049] The reverse compensation is specifically: according to the measured thickness deviation, the negative compensation height at different positions is calculated through a compensation calculation formula, and then the height of the ring belt at different positions of the skateboard mold cavity is adjusted to adjust the height of the mud distribution at different ring belt sections.

[0050] The compensation calculation formula is as follows:

[0051] H1=H2×r p ×α,

[0052] Wherein: H1 is the negative compensation height of the mud; H2 is the thickness of the formed brick; r p is the compression ratio of the mud; and a is a correction coefficient, which is set according to the volume ratio of the compensation amount of the mud at different positions to the volume after forming.

[0053] Operation example 1:

[0054] A negative compensation forming process for producing zircon-inlaid skateboard bricks by a full-automatic hydraulic machine, comprising the following steps:

[0055] Step S1: Prepare mud in proportion, and the weight ratio of the mud is: tabular corundum 62%, fused zircon mullite 20%, alumina micropowder 6%, Al2 2%, Si2%, B4C 1%, carbon material 4%, and phenolic resin 3%;

[0056] Step S2: uniformly mix the mud in step S1 by a high-speed mixer, the material with a particle size greater than 2 mm accounts for 15% in the mixed mud, the material with a particle size of 2-0.088 mm accounts for 55%, the material with a particle size of 0.088-0.04 mm accounts for 20%, and the material with a particle size less than 0.04 mm accounts for 10%, and then the mixed mud is detected, the moisture content of the mud is 1.1%, and the forming compression ratio of the mud is 1.6;

[0057] Step S3: The detected mud is hoisted to the press bin, the hydraulic press parameters are set according to the compression ratio of the mud detection, and the negative compensation method is used to start the brick pressing. During the molding process, the molding pressure, material height, molding thickness and thickness difference need to be controlled;

[0058] Step S4: Demolding, and measuring the size of the first molded brick, weighing it, and making appropriate adjustments until it meets the internal control requirements, then normally pressing according to the full-automatic mode.

[0059] The automatic negative compensation method in step S3 is as follows: obtaining thickness data and compensation parameters of each part, dividing compensation coefficients a of each part, casting hole compensation coefficient, and edge band compensation coefficient. According to the volume ratio of the compensation amount of the mud at different positions to the volume after molding, a is set.

[0060] Specifically, the zircon plate sliding plate has a casting hole thickness of 59 mm and an edge band thickness of 42 mm. The compression ratio of the rp mud detection is about 1.6. According to the volume ratio of the casting hole position to the mud volume, a is about 1 / 0.71=1.41. The compensation height of the casting hole mud is 59mm*(1.6-1)*1.41=49.9mm. The compensation height of the edge band mud is 42mm*(1.6-1)=25.2mm. The press controller inputs the set value, and the mold reaches the corresponding position before molding. In this case, according to this height, the first detection sliding plate size is obtained after molding. If the casting hole thickness of the sliding plate after molding is 60mm and the edge band thickness is 42mm, only the compensation height of the casting hole position needs to be reduced. If the thickness of the two edge bands after molding is >1mm, the compensation height of the two sides needs to be adjusted separately. After stable molding, the sliding plate size and weight are detected every 5min. If there is a change, the compensation parameters need to be corrected.

[0061] Comparison of different part indicators of zircon sliding plate:

[0062]

[0063] The zircon sliding plate is formed by using an electric screw. The number of sliding plates formed per shift is 40-50. The zircon plate sliding plate is formed by using a hydraulic press. The number of sliding plates formed per shift is 50-60. The number of sliding plates formed per shift using the new process and method is 100-150.

[0064] Operation example 2:

[0065] A negative compensation molding process for producing zircon sliding plate bricks by a full-automatic hydraulic press, comprising the following steps:

[0066] Step S1: Prepare the mud in proportion. The weight ratio of the mud is: 45% of electrically fused corundum, 30% of electrically fused zircon mullite or electrically fused zircon corundum, 10% of alumina powder, 2% of Si, 2% of B4C, 2% of BN, 5% of carbon material, and 4% of phenolic resin.

[0067] Step S2: The mud in step S1 is mixed uniformly by a high-speed mixer, the mixed mud contains 12% of materials with particle size greater than 2mm, 48% of materials with particle size of 2-0.088mm, 20% of materials with particle size of 0.088-0.04mm, and 20% of materials with particle size less than 0.04mm. Then the mixed mud is detected, the moisture content of the mud before molding is 0.9%, and the molding compression ratio of the mud is 1.5;

[0068] Step S3: The detected mud is hoisted to the press bin, the hydraulic machine parameters are set according to the compression ratio of the mud detection and in real time, the negative compensation method is used to start pressing the bricks, and the molding pressure, cloth height, molding thickness and thickness difference need to be controlled during molding;

[0069] Step S4: Demolding, and measuring the size, single weight of the first molded brick, and appropriately trimming until meeting the internal control requirements, and then normally pressing according to the full-automatic mode.

[0070] The automatic negative compensation method in step S3 is specifically as follows:

[0071] Taking the zircon ring slide plate with upward casting hole as an example, the thickness of the casting hole is 62mm, the thickness of the edge band is 42mm, the compression ratio of the rp mud detection is about 1.5, the volume ratio of the casting hole position to the mold cavity mud volume is about 1 / 1.16=0.86, and the compensation height of the casting hole mud is 62*(1.5-1)*0.86=26.7mm. The compensation height of the edge band mud can be set to 0mm. After molding, if the overall slide plate size is less than 42mm, the mud cloth height and the compensation amount of the casting hole mud can be increased.

[0072] Operation example 3:

[0073] A negative compensation molding process for producing zircon slide plate bricks by a full-automatic hydraulic machine, comprising the following steps:

[0074] Step S1: Preparing mud in proportion, and the weight ratio of the mud is: tabular corundum or fused corundum 75%, fused zircon mullite or fused zircon corundum 5%, alumina micropowder 10%, Al2 2%, BN 1%, carbon material 4%, and phenolic resin 3%;

[0075] Step S2: The mud in step S1 is mixed uniformly by a high-speed mixer, the mixed mud contains 12% of materials with particle size greater than 2mm, 48% of materials with particle size of 2-0.088mm, 20% of materials with particle size of 0.088-0.04mm, and 20% of materials with particle size less than 0.04mm. Then the mixed mud is detected, the moisture content of the mud before molding is 0.9%, and the molding compression ratio of the mud is 1.5;

[0076] Step S3: the detected mud is hoisted to the press bin, the hydraulic press parameters are set according to the compression ratio of the mud detection, and the negative compensation method is used to start pressing the brick, and the molding pressure, material height, molding thickness and thickness difference need to be controlled during molding;

[0077] Step S4: demolding, size measurement, single weight measurement and appropriate trimming are performed on the first molded green brick, and then the green brick is normally pressed according to the full-automatic mode.

[0078] The automatic negative compensation method in step S3 is as follows:

[0079] Taking the horizontal direction molding of the slide plate with no casting hole and embedded zircon plate as an example, before molding, the mud enters the mold cavity through the feeding port by jetting or air feeding or other ways, and by applying positive pressure, the mud quickly fills the entire cavity, and by setting the distance between different split molds, the volume difference of the mud filling at different positions is realized, and the overall density uniformity of the slide plate is improved. Referring to operation example 1, the casting hole thickness is 65 mm, the edge band thickness is 44 mm, the compression ratio of the rp mud detection is about 1.55, and according to the volume ratio of the green brick at different positions to the mud volume in the mold cavity, the compensation height of the casting hole mud is 65mm*(1.55-1)*1.33=47.5mm. And the compensation height of the edge band mud is 44mm*(1.55-1)=24.2mm. If the lower edge band thickness after molding is thicker than 44mm, the lower edge band mud compensation amount can be further reduced.

[0080] In the description of the present specification, the description of the terms "one embodiment", "example", "specific example" and the like means that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In the present specification, the illustrative description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0081] The basic principles, main features and advantages of the present application are shown and described above. It should be understood by those skilled in the art that the present application is not limited by the above embodiments, and the above embodiments and descriptions in the specification are only illustrative of the principles of the present application. Without departing from the spirit and scope of the present application, various changes and improvements can be made to the present application, and these changes and improvements all fall within the scope of the claimed present application.

Claims

1. A negative compensation molding process for producing zircon-embedded sliding plate bricks using a fully automatic hydraulic press, characterized in that, Includes the following steps: Step S1: Prepare the clay material according to the following proportions by weight: Component A 40-80%, Component B 0-35%, alumina micro powder 5-15%, antioxidant 3-8%, carbon material 1-8%, phenolic resin 3-5%; Step S2: The clay from Step S1 is mixed evenly using a high-speed mixer, and then the mixed clay is tested. Before molding, the moisture content of the clay is 0.9-1.2% by mass, and the molding compression ratio is 1.5-1.

7. Step S3: The tested clay material is hoisted to the press hopper. Based on the compression ratio of the tested clay material and the hydraulic press parameters are set in real time, the brick pressing is started using the negative compensation method. During the molding process, the molding pressure, material distribution height, molding thickness and thickness difference need to be controlled. Step S4: Demolding, measuring the size and weighing the first-formed brick blank, and making appropriate adjustments until the internal control requirements are met, then pressing normally in fully automatic mode. The negative compensation method in step S3 is specifically as follows: After the first sample is formed, the thickness deviation and torsional deformation at different positions are determined using the sample blank obtained from the first forming. Preliminary reverse compensation is performed based on the deviation. If the reverse compensation effect is confirmed by measurement after the second forming, and the effect is still not ideal, the above actions are repeated until the thickness deviation meets the internal control requirements. The reverse compensation specifically involves: calculating the negative compensation height at different positions based on the measured thickness deviation using a compensation calculation formula, and then adjusting the ring belt height at different positions of the slide mold cavity to adjust the mud material distribution height in different ring belt sections. The compensation calculation formula is as follows: ， Where: H1 is the negative compensation height of the clay material; H2 is the thickness of the formed brick blank; r p α is the compression ratio of the clay material; α is the correction coefficient, which is set according to the ratio of the clay material compensation volume to the volume after molding at different locations.

2. The negative compensation molding process for producing zircon-embedded sliding plate bricks using a fully automatic hydraulic press according to claim 1, characterized in that, Component A is tabular corundum or fused alumina, component B is fused zircon mullite or fused zircon alumina, and the antioxidant is composed of one or more of the metals Al, Si, B4C, and BN.

3. The negative compensation molding process for producing zircon-embedded sliding plate bricks using a fully automatic hydraulic press according to claim 1, characterized in that, In step S2, the mixed mud contains 10-15% material with a particle size >2mm, 45-60% material with a particle size of 2-0.088mm, 10-20% material with a particle size of 0.088-0.04mm, and 10-20% material with a particle size <0.04mm.

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