Ultra-porous double-medium lubrication crystallization casting system for aluminum bar and operation method of ultra-porous double-medium lubrication crystallization casting system

Abstract

The invention discloses an ultra-porous double-medium lubrication crystallization casting system for an aluminum bar and an operation method, and the ultra-porous double-medium lubrication crystallization casting system comprises a water tank platform, at least one oil discharge gas lubrication crystallizer assembly, a pulse oil supply system, an adjustable volume flow gas supply system, an aluminum liquid distribution launder assembly and a preheater, the oil-gas lubricating crystallizer assembly comprises a crystallizer body, a breathable graphite ring and a sealing assembly, an oil groove is formed in the crystallizer body, the oil groove is suitable for forming a lubricating film on the crystallization surface of molten aluminum, and the water tank platform is suitable for evenly distributing cooling water to the multiple crystallizers through the water distribution pipe; the pulse oil supply system comprises a stainless steel pulse oil supply pipeline, an oil injector and a frequency-adjustable pulse pump, can provide a more uniform cooling effect and a more stable lubricating film, can effectively prevent the defects of cold shut, cracks and the like of molten aluminum in the casting process, and improves the quality and production efficiency of aluminum bars.

Description

Technical Field

[0001] The invention relates to an ultra-porous dual-medium lubrication crystallization casting system for aluminum rods and an operating method thereof, belonging to the technical field of aluminum rod production equipment. Background Art

[0002] At present, the production of aluminum bars usually adopts semi-continuous casting. One of the key equipment involved is the crystallization casting machine. The main function of the crystallization casting machine is to solidify the molten aluminum liquid into aluminum bars. It has a direct impact on the quality of the aluminum bars. Traditional casting machines have certain limitations when cooling the aluminum bars. This may lead to defects such as cold shut and cracks on the surface of the aluminum bars, and the production efficiency and aluminum liquid utilization rate are low. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to overcome the defects of the existing technology and provide an ultra-porous dual-medium lubrication crystallization casting system and operation method for aluminum rods, which can provide a more uniform cooling effect and a more stable lubricating film, and can effectively prevent defects such as cold shut and cracks in the aluminum liquid during the casting process, thereby improving the quality and production efficiency of the aluminum rods.

[0004] In order to solve the above technical problems, the technical solution of the present invention is: an ultra-porous dual-medium lubricated crystallization casting system for aluminum rods, comprising: A water tank platform, wherein a water distribution pipe and a water distribution hole are provided inside the water tank platform. At least one row of oil-gas sliding crystallizer assemblies, the oil-gas sliding crystallizer assembly comprising a crystallizer body, a breathable graphite ring and a sealing assembly, the crystallizer body being provided with an oil groove, the oil groove being suitable for forming a lubricating film on the aluminum liquid crystallization surface, the water tank platform being suitable for evenly distributing cooling water to multiple crystallizers through the water distribution pipe; A pulse oil supply system, comprising a stainless steel pulse oil supply pipeline, an oil injector, and an adjustable frequency pulse pump. The adjustable frequency pulse pump can deliver lubricating oil to the oil tank of each crystallizer through the stainless steel pulse oil supply pipeline at a set frequency and duty cycle; An adjustable volume flow air supply system, comprising a float flowmeter, a pressure regulating device and an air pipeline, wherein the pressure regulating device is adapted to deliver compressed air at a predetermined flow rate through the air pipeline to the air rings of each crystallizer; An aluminum liquid distribution chute assembly, the aluminum liquid distribution assembly comprising a distribution plate and an adapter sleeve, the distribution plate being adapted to uniformly introduce the molten aluminum liquid into the crystallizer body; a preheater, which preheats the distribution plate by burning natural gas; a starter stand assembly, the starter stand assembly comprising a starter head that can be connected in a floating manner, the starter head being adapted to receive and hold the solid phase aluminum rod pulled out of the crystallizer; Furthermore, the distribution chute assembly is made of a refractory mixture.

[0005] Furthermore, the water tank platform is made of Q345 steel plates and square tubes welded and annealed and then machined as a whole. The top plate thickness of the water tank platform is 10-30 mm, and the bottom plate thickness is 10-20 mm. A detachable filter is installed at the hole position of the crystallizer body.

[0006] Furthermore, the oil-gas sliding crystallizer assembly is made of 6061 forged aluminum alloy, the surface of the oil-gas sliding crystallizer is anodized, and the graphite ring uses original imported breathable graphite.

[0007] Furthermore, the pulse oil supply system can adjust the pulse frequency to 0-20 Hz, and the oil volume adjustment range is 0-20 ml / t.

[0008] Furthermore, the interior of the aluminum liquid distribution chute assembly is coated with a boron nitride coating; The distribution plate and the adapter sleeve are made of medium-resistant mixed material and N17 carbon fiber plate respectively.

[0009] Furthermore, the starter head is made of 45# steel round bar.

[0010] Furthermore, the ultra-porous dual-medium lubricated crystallization casting system for aluminum rods also includes an anti-falling frame, which is welded from square tube grids and is arranged between the bottom of the water tank platform and the ingot starter head.

[0011] Furthermore, the ultra-porous dual-medium lubricated crystallization casting system for aluminum rods also includes a hanging rod device, which includes a crossbeam, a double-row short-link chain and a clamping plate.

[0012] The present invention also provides an operating method of a super porous dual-medium lubrication crystallization casting system for aluminum rods, comprising the following steps: S1, Equipment preparation stage: Start the preheater and preheat the distribution plate of the aluminum liquid distribution chute assembly through natural gas combustion; Turn on the adjustable volume flow air supply system, set the compressed air flow rate through the float flowmeter and pressure regulating device, and deliver a stable airflow to the breathable graphite ring; A pulse oil supply system is configured, and the pulse frequency (0~20Hz) and duty cycle of the lubricating oil are set by an adjustable frequency pulse pump, and lubricating oil is injected into the oil tank of the crystallizer to form a lubricating film.

[0013] S2. Aluminum liquid treatment and casting start-up: The molten aluminum liquid is poured into the distribution plate and evenly introduced into each crystallizer body through the adapter sleeve. The distribution water pipe of the water tank platform is started. The cooling water is evenly distributed to the crystallizer assembly through the water distribution hole to achieve initial solidification of the aluminum liquid. The ingot head of the ingot stand assembly rises to contact the solidified aluminum rod, and the aluminum rod is kept in position through the floating connection.

[0014] S3. Continuous casting control: Real-time adjustment of the oil volume of the pulse oil supply system (0~20ml / t) to maintain the thickness of the lubricating film in the crystallizer, monitoring the gas flow of the breathable graphite ring, and ensuring the stability of the gas-lubricating interface; adjusting the cooling water flow and preheating temperature according to the aluminum billet casting speed to prevent cold shut defects.

[0015] S4. End of casting and aluminum bar processing: stop injecting aluminum liquid, turn off the preheater and air supply system, keep the cooling water running until the aluminum bar is completely solidified, cut off the pulse oil supply, lower the ingot head to demould, support the aluminum bar with the anti-fall frame, move the hanging bar device, and use the crossbeam, double-row short link chain and pallet to transfer the aluminum bar.

[0016] After adopting the above technical solution, the present invention has the following beneficial effects: 1. In this invention, the design of the water distribution pipes and water distribution holes within the water tank platform, combined with the removable filter screen on the crystallizer assembly, ensures that the cooling water is extremely evenly distributed to each crystallizer body, achieving uniform cooling of the aluminum liquid solidification interface. The pulse oil supply system (0-20Hz frequency, 0-20ml / t oil volume) precisely controls the injection of lubricating oil into the oil tank in pulsed form. Combined with the adjustable volume flow air supply system to deliver a stable airflow to the breathable graphite ring, a thick and uniform air-lubricating film is formed on the crystallization surface (stable air-lubricating interface). This effectively reduces the frictional resistance between the aluminum rod and the crystallizer wall, significantly improves the surface smoothness of the aluminum rod, and avoids surface defects such as scratches and cracks.

[0017] 2. In the present invention, the preheater preheats the distribution plate by burning natural gas. Combined with the cooling water flow and preheating temperature control strategy that is adjusted in real time according to the casting speed, it effectively prevents the temperature of the molten aluminum from dropping suddenly at the beginning and during the casting process, significantly reducing the incidence of cold shut defects. Uniform cooling and stable lubrication also reduce the risk of cracking caused by thermal stress concentration or uneven friction. The design and material selection (refractory mixture, medium-refractory mixture, N17 carbon fiber plate, boron nitride coating) of the aluminum distribution chute assembly (particularly the distribution plate and adapter sleeve) ensure that molten aluminum flows quickly and evenly into multiple molds, improving pouring efficiency and first-time yield. The floating connection starter head design of the starter stand assembly effectively absorbs minor vibrations and positional deviations during the initial casting period, ensuring accurate aluminum bar positioning and smooth start-up. The anti-fall frame provides reliable support for the aluminum bars, preventing them from tipping over.

[0018] 3. In the present invention, the water tank platform is made of Q345 steel after welding and annealing, which is integrally processed, with strong structural rigidity and small deformation; the crystallizer body is made of 6061 forged aluminum and anodized, which is heat-resistant and wear-resistant; key components such as graphite rings are made of imported breathable graphite, the distribution chute is made of high-temperature resistant material and coated with boron nitride, and the ingot starter is made of 45# steel, which significantly improves the service life and operational reliability of the equipment in high-temperature and high-wear environments; After casting, the design of the rod hanging device (crossbeam, double-row short-link chain, and pallet) enables the solidified aluminum rods to be transferred safely and efficiently, improving overall operating efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a schematic diagram of the structure of a super porous dual-medium lubricated crystallization casting system for aluminum rods of the present invention. Figure 1 ; Figure 2 This is a schematic diagram of the structure of a super porous dual-medium lubricated crystallization casting system for aluminum rods of the present invention. Figure 2 . DETAILED DESCRIPTION

[0020] In order to make the contents of the present invention more clearly understood, the present invention is further described in detail below based on specific embodiments in conjunction with the accompanying drawings. Example

[0021] like Figure 1-2 As shown, a super porous dual-medium lubricated crystallization casting system for aluminum rods includes: Water tank platform 1, the water tank platform 1 is provided with a water distribution pipe and a water distribution hole. At least one row of oil-gas sliding crystallizer assemblies, the oil-gas sliding crystallizer assembly includes a crystallizer body 2, a breathable graphite ring and a sealing assembly. The crystallizer body 2 is provided with an oil tank, which is suitable for forming a lubricating film on the aluminum liquid crystallization surface. The water tank platform 1 is suitable for evenly distributing cooling water to multiple crystallizers through a distribution pipe; The pulse oil supply system includes a stainless steel pulse oil supply pipeline 3, an oil injector and an adjustable frequency pulse pump. The adjustable frequency pulse pump can deliver lubricating oil to the oil tank of each crystallizer through the stainless steel pulse oil supply pipeline 3 according to the set frequency and duty cycle; An adjustable volume flow air supply system, comprising a float flow meter, a pressure regulating device and an air line 4, wherein the pressure regulating device is adapted to deliver compressed air at a predetermined flow rate through the air line 4 to the air rings of each crystallizer; Aluminum liquid distribution chute assembly, the aluminum liquid distribution assembly includes a distribution plate 5 and an adapter sleeve, the distribution plate 5 is suitable for uniformly introducing the molten aluminum liquid into the crystallizer body 2; Preheater 6, which preheats the distribution plate 5 by burning natural gas; The starter stand assembly comprises a starter head 7 that can be connected in a floating manner. The starter head 7 is suitable for receiving the solid phase aluminum rod pulled out from the crystallizer and keeping it in position.

[0022] In this embodiment, the float flowmeter has a diameter of 25 mm and an air measurement range of 3-110 m 3 .

[0023] In this embodiment, the design of the water distribution pipes and water distribution holes within the water tank platform 1, combined with the removable filter screen on the crystallizer assembly, ensures that the cooling water is extremely evenly distributed to each crystallizer body 2, achieving uniform cooling of the aluminum liquid solidification interface. A pulsed oil supply system (0-20Hz frequency, 0-20ml / t oil volume) precisely controls the injection of lubricating oil into the oil tank in pulses. This, combined with the stable air flow delivered to the breathable graphite rings by the adjustable volumetric flow rate air supply system, forms a uniformly distributed and thick air-lubricating film on the crystallization surface (stable air-lubricating interface). This effectively reduces the frictional resistance between the aluminum rod and the crystallizer wall, significantly improves the surface smoothness of the aluminum rod, and avoids surface defects such as scratches and cracks.

[0024] like Figure 1-2 As shown, the distribution chute assembly is made of a refractory mix.

[0025] like Figure 1-2 As shown, the water tank platform 1 is made of Q345 steel plate and square tube welded and annealed as a whole and machined. The top plate thickness of the water tank platform 1 is 10-30mm and the bottom plate thickness is 10-20mm. A detachable filter is installed at the hole position of the crystallizer body 2.

[0026] like Figure 1-2 As shown, the oil-gas sliding crystallizer assembly is made of 6061 forged aluminum alloy, the surface of the oil-gas sliding crystallizer is anodized, and the graphite ring is made of original imported breathable graphite; The specifications of the graphite ring in this embodiment are as follows: Porosity: 10Vol.%~15Vol.%; Thermal conductivity: 80W / (m·K)~105W / (m·K); Compressive strength: 40MPa~80MPa; Grayscale: 20~50PPM like Figure 1-2 As shown, the pulse oil supply system can adjust the pulse frequency from 0 to 20 Hz, and the oil volume adjustment range is 0 to 20 ml / t.

[0027] like Figure 1-2 As shown, the interior of the aluminum liquid distribution chute assembly is coated with a boron nitride coating; The distribution plate 5 and the adapter sleeve are made of medium-resistant mixed material and N17 carbon fiber plate respectively.

[0028] In this embodiment, the surface of the aluminum liquid distribution trough needs to be cleaned before coating to ensure that the surface of the aluminum liquid distribution trough is free of oil stains and oxides and is preheated to 200°C-300°C.

[0029] like Figure 1-2 As shown, the starter head 7 is made of 45# steel round bar.

[0030] like Figure 1-2 As shown, the ultra-porous dual-medium lubricated crystallization casting system for aluminum rods also includes an anti-falling frame, which is welded from square tube grids and is arranged between the bottom of the water tank platform 1 and the ingot starter 7.

[0031] In this embodiment, the specifications and dimensions of the square tube are as follows: Cross-sectional dimensions: 40mm×40mm; Wall thickness: 1.0mm~1.8mm; Load-bearing capacity: 0.5kg~200kg.

[0032] like Figure 1-2 As shown, the ultra-porous dual-medium lubricated crystallization casting system for aluminum rods also includes a hanging rod device, which includes a crossbeam, a double-row short-link chain and a clamping plate. The rated load of the crossbeam is 5t-15t, the diameter of the double-row short-link chain is 20mm, and its breaking tensile force is 770KN.

[0033] In this embodiment, the preheater 6 preheats the distribution plate 5 by burning natural gas. Combined with a cooling water flow rate and preheating temperature control strategy that adjusts in real time according to the casting speed, this effectively prevents a sudden temperature drop in the molten aluminum at the beginning and during the casting process, significantly reducing the incidence of cold shut defects. Uniform cooling and stable lubrication also reduce the risk of cracking caused by thermal stress concentration or uneven friction. The design and material selection (refractory mixture, medium-refractory mixture, N17 carbon fiber plate, boron nitride coating) of the aluminum distribution chute assembly (particularly the distribution plate 5 and adapter sleeve) ensure that molten aluminum flows quickly and evenly into multiple molds, improving pouring efficiency and first-time yield. The floating connection of the starter head 7 in the starter stand assembly effectively absorbs minor vibrations and positional deviations during the initial casting phase, ensuring accurate aluminum bar positioning and smooth start-up. The anti-fall frame provides reliable support for the aluminum bars, preventing them from tipping over.

[0034] In this embodiment, the water tank platform 1 is made of Q345 steel after welding and annealing, which is integrally processed, with strong structural rigidity and small deformation; the crystallizer body 2 is made of 6061 forged aluminum and anodized, which is heat-resistant and wear-resistant; key components such as graphite rings are made of imported breathable graphite, the distribution chute is made of high-temperature resistant material and coated with boron nitride, and the ingot starter 7 is made of 45# steel, all of which significantly improve the service life and operational reliability of the equipment in high-temperature and high-wear environments; After casting, the design of the rod hanging device (crossbeam, double-row short-link chain, and pallet) enables the solidified aluminum rods to be transferred safely and efficiently, improving overall operating efficiency. Example

[0035] This embodiment also provides a method for operating an ultra-porous dual-medium lubricated crystallization casting system for aluminum rods, comprising the following steps: S1, equipment preparation stage: start the preheater 6 to preheat the distribution plate 5 of the aluminum liquid distribution chute assembly through natural gas combustion; Turn on the adjustable volume flow air supply system, set the compressed air flow rate through the float flowmeter and pressure regulating device, and deliver a stable airflow to the breathable graphite ring; A pulse oil supply system is configured, and the pulse frequency of the lubricating oil is set to 0~20Hz and the duty cycle through an adjustable frequency pulse pump, and lubricating oil is injected into the crystallizer oil tank to form a lubricating film.

[0036] S2. Aluminum liquid treatment and casting start-up: Molten aluminum liquid is poured into the distribution plate 5 and evenly introduced into each crystallizer body 2 through the adapter sleeve. The distribution water pipe of the water tank platform 1 is started. The cooling water is evenly distributed to the crystallizer assembly through the water distribution hole to achieve initial solidification of the aluminum liquid. The ingot head 7 of the ingot stand assembly rises to contact the solidified aluminum rod, and the aluminum rod head is kept in place by the floating connection. position.

[0037] S3. Continuous casting control: Real-time adjustment of the oil volume of the pulse oil supply system from 0 to 20 ml / t to maintain the thickness of the lubricating film in the crystallizer, monitoring the gas flow of the breathable graphite ring, and ensuring the stability of the gas-lubricating interface; adjusting the cooling water flow and preheating temperature according to the aluminum billet casting speed to prevent cold shut defects.

[0038] S4. End of casting and aluminum bar processing: stop injecting aluminum liquid, turn off the preheater 6 and the air supply system, keep the cooling water running until the aluminum bar is completely solidified, cut off the pulse oil supply, lower the ingot head 7 to demould, support the aluminum bar with the anti-fall frame, move the hanging bar device, and use the crossbeam, double-row short link chain and pallet to transfer the aluminum bar.

[0039] The above specific embodiments further illustrate the technical problems, technical solutions and beneficial effects solved by the present invention. It should be understood that the above are only specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. An ultra-porous dual-medium lubricated crystallization casting system for aluminum rods, characterized in that: include: A water tank platform (1) is provided with a water distribution pipe and a water distribution hole inside the water tank platform (1). At least one row of oil-gas sliding crystallizer components, the oil-gas sliding crystallizer components comprising a crystallizer body (2), a breathable graphite ring and a sealing component, the crystallizer body (2) being provided with an oil groove, the oil groove being suitable for forming a lubricating film on the aluminum liquid crystallization surface, the water tank platform (1) being suitable for evenly distributing cooling water to a plurality of crystallizers through the distribution water pipe; A pulse oil supply system, the pulse oil supply system comprising a stainless steel pulse oil supply pipeline (3), an oil injector and an adjustable frequency pulse pump, the adjustable frequency pulse pump being able to deliver lubricating oil to the oil tank of each crystallizer through the stainless steel pulse oil supply pipeline (3) at a set frequency and duty cycle; An adjustable volume flow air supply system comprises a float flow meter, a pressure regulating device and an air line (4), wherein the pressure regulating device is adapted to convey compressed air at a predetermined flow rate through the air line (4) to the air rings of each crystallizer; An aluminum liquid distribution chute assembly, the aluminum liquid distribution assembly comprising a distribution plate (5) and an adapter sleeve, the distribution plate (5) being suitable for uniformly introducing the molten aluminum liquid into the crystallizer body (2); a preheater (6), wherein the preheater (6) preheats the distribution plate (5) by burning natural gas; A starter frame assembly comprises a starter head (7) that can be connected in a floating manner. The starter head (7) is suitable for receiving a solid phase aluminum rod head pulled out from the crystallizer and keeping it in position.

2. The ultra-porous dual-medium lubricated crystallization casting system for aluminum rods according to claim 1, characterized in that: The distribution chute assembly is made of a refractory mixture.

3. The ultra-porous dual-medium lubricated crystallization casting system for aluminum rods according to claim 1, characterized in that: The water tank platform (1) is made of Q345 steel plates and square tubes welded and annealed and then machined as a whole. The top plate thickness of the water tank platform (1) is 10-30 mm, and the bottom plate thickness is 10-20 mm. A detachable filter screen is installed at the hole position of the crystallizer body (2).

4. The ultra-porous dual-medium lubricated crystallization casting system for aluminum rods according to claim 1, characterized in that: The oil-gas sliding crystallizer component is made of 6061 forged aluminum alloy, the surface of the oil-gas sliding crystallizer is anodized, and the graphite ring is made of original imported breathable graphite.

5. The ultra-porous dual-medium lubricated crystallization casting system for aluminum rods according to claim 1, characterized in that: The pulse oil supply system can adjust the pulse frequency to 0-20 Hz, and the oil quantity adjustment range is 0-20 ml / t.

6. The ultra-porous dual-medium lubricated crystallization casting system for aluminum rods according to claim 1, characterized in that: The interior of the aluminum liquid distribution chute assembly is coated with a boron nitride coating; The distribution plate (5) and the adapter sleeve are respectively made of a medium-resistant mixed material and an N17 carbon fiber plate.

7. The ultra-porous dual-medium lubricated crystallization casting system for aluminum rods according to claim 1, characterized in that: The ingot starter (7) is made of 45# steel round bar.

8. The ultra-porous dual-medium lubricated crystallization casting system for aluminum rods according to claim 1, characterized in that: It also includes an anti-fall frame, which is welded from square tube grilles and is arranged between the bottom of the water tank platform (1) and the ingot starter (7).

9. The ultra-porous dual-medium lubricated crystallization casting system for aluminum rods according to claim 1, characterized in that : It also includes a hanging rod device, which includes a crossbeam, a double-row short-link chain and a clamping plate.

10. An operating method of the super porous dual-medium lubrication crystallization casting system for aluminum rods according to any one of claims 1 to 9, characterized in that: The following steps are involved: S1, equipment preparation stage: start the preheater (6) to preheat the distribution plate (5) of the aluminum liquid distribution chute assembly through natural gas combustion; Turn on the adjustable volume flow air supply system, set the compressed air flow rate through the float flowmeter and pressure regulating device, and deliver a stable airflow to the breathable graphite ring; Equipped with a pulse oil supply system, the pulse frequency (0~20Hz) and duty cycle of the lubricating oil are set by an adjustable frequency pulse pump, and lubricating oil is injected into the oil tank of the crystallizer to form a lubricating film; S2, aluminum liquid treatment and casting start: molten aluminum liquid is injected into the distribution plate (5), and evenly introduced into each crystallizer body (2) through the adapter sleeve, and the distribution water pipe of the water tank platform (1) is started. The cooling water is evenly distributed to the crystallizer assembly through the water distribution hole to achieve the initial solidification of the aluminum liquid. The ingot head (7) of the ingot stand assembly rises to contact the solidified aluminum rod, and the aluminum rod is kept in position through the floating connection; S3. Continuous casting control: Real-time adjustment of the oil volume of the pulse oil supply system (0-20 ml / t) to maintain the thickness of the lubricating film in the crystallizer, monitoring the gas flow of the breathable graphite ring to ensure the stability of the gas-lubricating interface; adjusting the cooling water flow and preheating temperature according to the aluminum billet casting speed to prevent cold shut defects; S4. End of casting and aluminum bar processing: stop injecting aluminum liquid, turn off the preheater (6) and the air supply system, keep the cooling water running until the aluminum bar is completely solidified, cut off the pulse oil supply, lower the ingot head (7) to demould, support the aluminum bar with the anti-fall frame, move the hanging bar device, and use the crossbeam, double-row short link chain and pallet to transfer the aluminum bar.

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