High-capacity coreless induction furnace copper mold device and using method

Abstract

The invention relates to a high-capacity coreless induction furnace copper mold device and a using method thereof, and belongs to the technical field of non-ferrous metal casting. The device comprises a barrel, a flange and a barrel bottom, the barrel is in an inverted circular truncated cone shape and is formed by curling and welding a copper plate, and the flange is connected with the small-diameter end of the barrel in a sealed mode through welding; and the cylinder bottom is hermetically connected with the large-diameter end of the cylinder body through welding. A plurality of exhaust through holes are formed in the device and used for exhausting gas. The copper mold device directly melts in the using process, the traditional demolding procedure is omitted, molten copper can be used as a raw material for casting production, the production efficiency is improved, and the furnace life is prolonged. The device is simple in design, low in cost, suitable for building coreless furnace hearths of different tonnages, capable of solving the problem that the hearths are possibly damaged due to demolding of a traditional steel mold, and widely suitable for the field of non-ferrous metal casting.

Description

Technical Field

[0001] The invention relates to the technical field of nonferrous metal casting, and in particular to a large-capacity coreless induction furnace copper mold device and a use method thereof. Background Art

[0002] In the non-ferrous metal casting industry, coreless induction furnaces have been widely used due to their high melting efficiency, fast brand change and furnace cleaning, high efficiency of furnace shutdown and old furnace reopening, and thorough emptying. However, the construction of the furnace of the coreless induction furnace is a very critical process. Traditionally, the furnace construction mold is usually made of steel molds. The first built furnace needs to be sintered in the furnace, demolded during the furnace baking process, and then continue to heat up to further sinter the refractory material. However, due to the large melting capacity of the furnace (such as 20 tons) and the large mold volume, the mold may be deformed during the demoulding process due to uneven furnace temperature, and then local refractory materials are often taken out during the demoulding process, resulting in local damage to the furnace refractory materials. Although the refractory material can be repaired and remedied, this will seriously affect the overall furnace life. Summary of the invention

[0003] To solve the above problems, the present invention provides a large-capacity coreless induction furnace copper mold device and a method of use. The device has a simple structure, is easy to process, has low cost, can be directly melted and recycled, avoids the demolding process, and improves production efficiency and furnace life.

[0004] According to the technical solution provided by the present invention, on the one hand, a large-capacity coreless induction furnace copper mold device is provided, comprising a cylinder, a flange and a cylinder bottom, wherein the cylinder is in an inverted truncated cone shape and is formed by curling and welding of copper plates; the flange is in an annular shape and is sealed and connected to the large-diameter end of the cylinder by welding, and has a plurality of long slot holes evenly distributed along the circumference thereof for hoisting and fixing the vibrator; the cylinder bottom is in a circular shape and is sealed and connected to the small-diameter end of the cylinder by welding; wherein a plurality of exhaust through holes are provided on the side wall and the cylinder bottom for exhausting gas, and the flange and the cylinder bottom are both cut and formed by copper plates.

[0005] As a large-capacity coreless induction furnace copper mold device of the present invention, further, the angle between the busbar of the cylinder and the central axis is 4°.

[0006] As a large-capacity coreless induction furnace copper mold device of the present invention, further, the outer joint of the bottom of the copper mold device is circumferentially processed with a fillet of R6mm.

[0007] In another aspect, the present invention further provides a method for using a large-capacity coreless induction furnace copper mold device, comprising:

[0008] Lay the refractory material for the furnace bottom;

[0009] Through the long slotted hole of the flange, the copper mold device is hoisted to the top of the furnace and slowly placed on the built furnace bottom;

[0010] Adjust the copper mold device to be concentric with the center of the furnace and fix it;

[0011] Pour the refractory material into the annular cavity formed between the copper mold device and the furnace coil, and build it layer by layer;

[0012] Use damp material to seal the furnace mouth;

[0013] Fill the furnace with copper material until the copper mold device is full;

[0014] Increase the temperature of the oven gradually until the copper mold is completely melted;

[0015] Continue to increase the power and slowly smelt the material until the furnace is filled with molten copper;

[0016] Raise the temperature of the copper liquid to 1200°C, remove the slag, and cover with charcoal;

[0017] After keeping at 1200-1250℃ for 3-5 hours, it returns to normal production.

[0018] Beneficial effects of the present invention:

[0019] The present invention provides a large-capacity coreless induction furnace copper mold device and a method for using the same. The large-capacity coreless induction furnace copper mold device has the advantages of simple structure and easy processing. It is composed of three parts: a flange, a cylinder and a cylinder bottom. The material is self-produced copper material with low production cost. The device can be directly melted during the baking process, eliminating the traditional demoulding process. The melted copper liquid can be directly used as the raw material for casting production, reducing the feeding time and improving production efficiency. An exhaust hole is provided on the copper mold device, which solves the problem that the gas in the refractory material cannot be discharged smoothly during the baking process, improves the quality of the copper liquid, and avoids the occurrence of pore defects in the ingot. In addition, the device effectively solves the risk that the original steel mold demoulding link may cause damage to the furnace, and prolongs the life of the furnace; according to different specification requirements, copper mold devices of different specifications are designed to meet the construction and use of coreless furnaces of different tonnages, and are widely applicable to the field of non-ferrous metal casting, solving the long-standing technical problems in the industry, meeting the needs of the market and users, with low investment and easy promotion. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic cross-sectional view of the structure of a large-capacity coreless induction furnace copper mold device of the present invention;

[0021] Figure 2 It is a top view structural schematic diagram of a large-capacity coreless induction furnace copper mold device of the present invention.

[0022] In the figure: cylinder body 1, flange 2, cylinder bottom 3, long slot hole 4, exhaust through hole 5. DETAILED DESCRIPTION

[0023] The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments:

[0024] like Figure 1 , Figure 2 As shown, the large-capacity coreless induction furnace copper mold device of the present invention is mainly composed of three parts: a cylinder 1, a flange 2 and a cylinder bottom 3.

[0025] The cylinder 1 is made of a whole 12mm thick copper plate that is curled and welded, and is in the shape of an inverted truncated cone. The angle between the generatrix of the cylinder 1 and the central axis is 4°. 90 φ2mm exhaust holes 4 are evenly arranged on the wall of the cylinder 2 as exhaust channels when the furnace refractory material is baked.

[0026] The flange 2 is cut from 12mm thick copper plate and is in a circular shape. It is sealed and connected to the large diameter end of the cylinder 1 by welding. Four long slot holes 4 are evenly distributed along the circumference on it for fixing and installing the vibrator. It can also be used as a hoisting hole for hoisting the copper mold device.

[0027] The bottom 3 is made of 12 mm thick copper plate and is circular in shape. It is sealed and connected to the small diameter end of the cylinder body (1) by welding. Four φ8 mm exhaust holes 4 are evenly arranged on the bottom 3 at a distance of φ600 mm from the center, serving as exhaust channels when the furnace bottom refractory material is baked.

[0028] After the cylinder 1, flange 2 and cylinder bottom 3 are processed separately, they are welded as a whole. Finally, a R6mm fillet is processed around the outer joint of the bottom of the copper mold device.

[0029] The copper mold device of the present invention can be designed into different specifications and sizes according to the requirements of furnaces with different capacities. Two specific embodiments are given below:

[0030] Example 1

[0031] Applicable to 20-ton melting furnace. The copper mold device has an upper diameter of 1376mm, a lower diameter of 1200mm, and a height of 2515mm.

[0032] Example 2

[0033] Applicable to 10-ton melting furnace. The copper mold device has an upper diameter of 1088mm, a lower diameter of 950mm, and a height of 2000mm.

[0034] The method of using the copper mold device of the present invention is as follows:

[0035] Before using the copper mold device, the furnace builders first build the furnace bottom, and then use a crane to hang it in the long slot hole 4 of the copper mold device flange 2 through a steel wire rope, and steadily hang it above the furnace, and then slowly fall on the built furnace bottom. Use auxiliary tools to ensure that the copper mold device is concentric with the furnace coil and the thickness of the refractory material is consistent. Then use auxiliary tools to fix the copper mold device to prevent the vibrator from moving during the construction process. After being vibrated by the vibrator, the furnace mouth is finally sealed with wet material. The construction of the coreless furnace hearth can be completed with high quality. At this time, the copper mold is still embedded in the built furnace, and the furnace charge in the copper mold is as solid and full as possible. The gap can be filled with broken edge materials. After the copper material is filled, the furnace is heated step by step. During the furnace baking process, the gas in the charge is continuously discharged smoothly through the exhaust through hole 5 set on the copper mold device. Continue to heat up until the copper mold is completely melted, continue to increase the power, slowly melt the material, fill the furnace, raise the copper liquid temperature to 1200℃, remove the slag, and cover the charcoal. Keep the copper liquid at 1200-1250℃ for 3-5 hours. After the insulation is over, it can be transferred to normal production. The melted copper mold device can be directly recycled and reused as a smelting raw material, reducing the demoulding process. It solves the problem that the gas in the refractory material cannot be discharged smoothly during the oven baking process, ensures the quality of the oven, and increases the furnace life.

Claims

1. A large-capacity coreless induction furnace copper mold device, comprising a cylinder (1), a flange (2) and a cylinder bottom (3), characterized in that The cylinder (1) is in the shape of an inverted truncated cone and is formed by curling and welding a copper plate; the flange (2) is in the shape of a circular ring and is sealed and connected to the large diameter end of the cylinder (1) by welding, and has a plurality of long slot holes (4) evenly distributed along the circumference thereof for hanging and fixing the vibrator; the cylinder bottom (3) is in the shape of a circular ring and is sealed and connected to the small diameter end of the cylinder (1) by welding; wherein a plurality of exhaust holes (5) are provided on the side wall of the cylinder (1) and the cylinder bottom (3) for exhausting gas, and the flange (2) and the cylinder bottom (3) are both cut and formed by a copper plate.

2. A large-capacity coreless induction furnace copper mold device according to claim 1, characterized in that: The included angle between the generatrix of the cylinder (1) and the central axis is 4°.

3. A large-capacity coreless induction furnace copper mold device according to claim 1, characterized in that: The outer joint of the bottom of the copper mold device is processed with a fillet of R6mm around the periphery.

4. A method for using the large-capacity coreless induction furnace copper mold device according to any one of claims 1 to 3, characterized in that: include: Lay the refractory material for the furnace bottom; Through the long slot hole (4) of the flange, the copper mold device is hoisted to the top of the furnace and slowly placed on the built furnace bottom; Adjust the copper mold device to be concentric with the center of the furnace and fix it; Pour the refractory material into the annular cavity formed between the copper mold device and the furnace coil, and build it layer by layer; Use damp material to seal the furnace mouth; Fill the furnace with copper material until the copper mold device is full; Increase the temperature of the oven gradually until the copper mold is completely melted; Continue to increase the power and slowly smelt the material until the furnace is filled with molten copper; Raise the temperature of the copper liquid to 1200°C, remove the slag, and cover with charcoal; After keeping at 1200-1250℃ for 3-5 hours, it returns to normal production.

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