Working roll pre-rotation guide and gradient controlled cooling centrifugal composite equipment and method
Patent Information
- Application Number
- CN202611208417.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-08-11
- Publication Date
- 2026-09-15
Smart Images
Figure CN122746428A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of centrifugal casting of rolls and composite roll manufacturing technology, specifically to a centrifugal composite equipment and method for pre-spinning and gradient controlled cooling of work rolls. Background Technology
[0002] Extra-large work rolls are key core components in modern metallurgical industry, and their performance directly affects the quality of rolled plates, production efficiency, and manufacturing costs. With the development of metallurgical equipment towards larger size, higher efficiency, and higher precision, higher requirements are placed on the dimensional stability, load-bearing capacity, wear resistance, thermal fatigue resistance, and service life of work rolls. Specifically, extra-large work rolls refer to work rolls with larger roll body dimensions, larger single-roll mass, and larger heat capacity. Based on existing centrifugal casting roll engineering examples, extra-large work rolls can be work rolls with a roll body diameter of not less than 800mm, a roll body length of not less than 3000mm, or a single-roll mass of not less than 10t, or other larger work rolls.
[0003] Existing technologies for manufacturing ultra-large composite work rolls mainly include centrifugal composite casting, electroslag casting, continuous casting, inlay casting, hot isostatic pressing, and spray casting. Among these, centrifugal composite forming technology has advantages such as relatively simple equipment, high production efficiency, and dense casting structure, and has become an important method in the manufacturing of composite work rolls.
[0004] However, during the centrifugal composite forming process of ultra-large work rolls, when the pouring direction of the liquid metal does not match the rotation direction of the cold mold, problems such as forward impact of the liquid flow, splashing, air entrapment, and turbulence can easily occur, thus affecting the spreading stability of the molten metal on the inner wall of the cold mold. At the same time, due to the large size and high heat capacity of the roll, the cooling intensity of different areas during solidification is inconsistent, which can easily lead to problems such as element segregation, uneven coating structure, unstable interface fusion, and differences in roll body performance.
[0005] Therefore, there is an urgent need to provide a centrifugal composite device and method that can achieve pre-swirl guidance of liquid metal during the casting stage and zoned gradient controlled cooling during the solidification stage, so as to improve the filling stability, microstructure uniformity and performance consistency of the centrifugal composite process of ultra-large working rolls. Summary of the Invention
[0006] In order to overcome the shortcomings of the prior art, the purpose of this application is to provide a centrifugal composite equipment and method for pre-spinning and guiding the working roll and gradient controlled cooling, so as to solve the problems of molten metal impact turbulence, unstable filling, uneven cooling and roller performance fluctuation in the existing centrifugal composite forming process.
[0007] Specifically, on the one hand, this application provides a working roller pre-swirl guiding and gradient controlled cooling centrifugal composite device, which includes a pre-swirl guiding casting system, a gradient controlled cooling system and a centrifugal composite system. The centrifugal composite system includes a horizontal cooling structure, a double support roller system and a drive unit. The horizontal cooling structure is cylindrical, the double support roller system is used to support the horizontal cooling structure, and the drive unit is connected to the double support roller system for transmission. The pre-swirl guiding and casting system is set at the feed end of the horizontal cold-form structure. The pre-swirl guiding and casting system includes a feed hopper, a flow channel guiding section, a lateral tangential discharge section and a bottom support. The feed hopper is connected to the feed end of the flow channel guiding section, the lateral tangential discharge section is connected to the discharge end of the flow channel guiding section, and the bottom support is used to support and position the flow channel guiding section and the lateral tangential discharge section. The flow channel guide section includes a first top plate, a first bottom plate, a first flow guide side plate, and a second flow guide side plate. The first top plate, the first bottom plate, the first flow guide side plate, and the second flow guide side plate enclose and form a flow channel for the flow of liquid metal. The lateral tangential discharge section includes a second top plate, a second bottom plate, a first discharge side plate, a second discharge side plate, and an end sealing plate. The second top plate, the second bottom plate, the first discharge side plate, and the second discharge side plate enclose a flow stabilizing buffer cavity. A lateral tangential discharge port is provided on the first discharge side plate or the second discharge side plate. The flow stabilizing buffer chamber is equipped with opposing flow guiding and limiting plate groups and multi-stage tangential flow guiding plate groups. The opposing flow guiding and limiting plate groups include upper and lower flow guiding and limiting plates arranged opposite each other, forming a flow limiting and guiding channel that communicates with the lateral tangential discharge port between the upper and lower flow guiding and limiting plates. The multi-stage tangential flow guiding plate groups include several spaced-apart flow guiding plates, with the flow guiding surface of the flow guiding plates inclined toward the lateral tangential discharge port. The liquid discharge direction of the lateral tangential discharge port corresponds to the rotational tangential direction of the inner wall of the horizontal cold-formed structure at the casting point. The gradient cooling system includes a support frame, layered cooling pipes, cooling medium nozzles, flow regulating valves, and a cooling medium supply unit.
[0008] Preferably, the first top plate, the first bottom plate, the first guide side plate, and the second guide side plate are fixedly connected by welding to form an integrally formed flow channel guide section; the flow channel guide section can be installed in a forward or mirror manner according to the rotation direction of the horizontal cold-formed structure.
[0009] Preferably, a transition guide surface is provided on the side of the second bottom plate near the lateral tangential discharge port. The transition guide surface is used to guide the liquid metal from axial flow to lateral tangential flow. The lateral tangential discharge port is rectangular. The end sealing plate is provided at the axial end of the flow stabilizing buffer chamber. The side of the end sealing plate facing the flow stabilizing buffer chamber forms an inclined guide surface. An inclination angle γ of the end sealing plate is formed between the inclined guide surface and the axial direction of the lateral tangential discharge section. γ is 10° to 45°.
[0010] Preferably, the upper flow guide limiting plate and the lower flow guide limiting plate are arranged in parallel.
[0011] Preferably, the multi-stage tangential guide plate assembly includes at least two guide plates, each guide plate is arranged at intervals along the flow direction of the liquid metal, and a flow-dividing channel is formed between adjacent guide plates; the multi-stage tangential guide plate assembly realizes the step-by-step flow guidance of liquid metal by changing the spacing between adjacent guide plates or changing the tilt angle of each guide plate; Horizontal spacing between adjacent guide vanes along the direction of liquid metal flow Decreasing according to an arithmetic progression, satisfying: ; in, The horizontal spacing between the i-th adjacent guide vanes This refers to the horizontal spacing of the first level. The spacing decreases in increments, i = 1, 2, ..., n-1, where n is the total number of guide vanes, and >0.
[0012] Preferably, each guide vane forms a guide vane inclination angle with respect to the axial direction of the lateral tangential outlet section. The inclination angle of each guide vane increases progressively along the direction of liquid metal flow and satisfies: 10° ≤ < <...< <...< ≤30°, so that the liquid metal gradually transitions from axial flow to lateral tangential flow, wherein, Let be the inclination angle of the j-th guide vane, where j = 1, 2, ..., n, and n is the total number of guide vanes. Each branch channel formed between adjacent guide vanes creates a liquid metal outflow direction at the outlet. The outflow angle of the branch channel is formed between the liquid metal outflow direction and the axial direction of the lateral tangential outlet section. The outflow angle of the h-th branch channel is denoted as . h=1,2,...,n-1, and the total number of diversion channels is n-1. The range is from 10° to 45°.
[0013] Preferably, the liquid discharge direction of the lateral tangential outlet forms a tangential matching angle with the rotational tangential direction of the inner wall of the horizontal cold-formed structure at the casting point. Tangential matching angle The range is from 0° to 30°.
[0014] Preferably, the number of layers of the stratified cooling pipeline is two or more, and each layer of the stratified cooling pipeline is arranged in layers along the height direction of the support frame. The cooling medium nozzles are connected to the stratified cooling pipelines and are set towards the outer surface of the horizontal cooling structure. The flow rate of each layer of the stratified cooling pipeline is independently controlled.
[0015] Preferably, the flow regulating valve is used to regulate the flow rate of the cooling medium in each layer of the cooling pipe to achieve zoned gradient controlled cooling in the centrifugal composite forming process. The cooling medium nozzles are set on both sides of the horizontal cooling structure. The spray direction of each cooling medium nozzle is consistent with the rotational tangent direction of the outer circular surface of the horizontal cooling structure at the corresponding spray point or forms a spray matching angle θ, which is 0° to 30°.
[0016] On the other hand, this application also provides a centrifugal composite forming method for a centrifugal composite device for pre-spinning and guiding flow of work rolls and gradient controlled cooling, which includes the following steps: S1. Equipment adjustment: Set the pre-swirl guiding pouring system at the feed end of the horizontal cold-formed structure, and adjust the position of the lateral tangential discharge port so that the liquid discharge direction of the lateral tangential discharge port corresponds to the rotation tangential direction of the inner wall of the horizontal cold-formed structure at the pouring point. S2. Adjust the horizontal cold-formed structure: Start the drive unit and drive the horizontal cold-formed structure to rotate around its axis through the double support roller system, so that the horizontal cold-formed structure reaches the preset centrifugal composite speed. S3, Pre-swirl guiding pouring: Liquid metal is injected into the flow channel guide section through the feed funnel. After being guided by the flow channel guide section, the liquid metal enters the lateral tangential discharge section. Under the combined action of the flow stabilizing buffer chamber, end sealing plate, opposed flow limiting plate group and multi-stage tangential flow guiding plate group, the axial flow gradually changes to lateral tangential flow. Then, it enters the horizontal cold mold structure through the lateral tangential discharge port. When liquid metal enters the horizontal cooling structure through the lateral tangential outlet, the relationship between the tangential velocity component of the liquid metal and the linear velocity of the inner wall of the horizontal cooling structure satisfies: ; In the formula, The pre-spin velocity matching coefficient is... The velocity at which liquid metal flows out tangentially from the side outlet. The tangential matching angle is the direction of liquid discharge from the lateral tangential outlet and the direction of rotational tangential of the inner wall of the horizontal cold-formed structure at the pouring point. For the cold type of angular velocity, The inner radius of the cold type; by controlling the pre-spinning speed matching coefficient To control the relationship between the tangential velocity component of the liquid metal and the linear velocity of the inner wall of the horizontal cold-formed structure; S4. Centrifugal composite forming: The liquid metal entering the horizontal cold forming structure adheres to the inner wall of the horizontal cold forming structure under the action of centrifugal force and spreads along the circumference to form the outer layer of liquid metal of the working roller; after the outer layer of liquid metal of the working roller reaches the preset composite process state, the core liquid metal is introduced so that the core liquid metal and the outer layer of liquid metal of the working roller form a composite interface. S5. Gradient controlled cooling solidification: Start the gradient controlled cooling system, adjust the flow rate of the cooling medium in each layer of cooling pipes through the flow regulating valve, and spray the cooling medium onto the outer surface of the horizontal cooling structure through the cooling medium nozzle, so that the molten metal solidifies and forms under the zoned gradient controlled cooling conditions. The cooling medium flow rate of each layer of cooling pipes is distributed according to a preset gradient coefficient, and the relationship satisfies: ; In the formula, Let r be the flow rate of the cooling medium in the r-th layer of cooling pipes. Based on the cooling medium flow rate, This represents the gradient adjustment coefficient corresponding to the r-th layer of cooling pipes; by setting different... value.
[0017] Compared with the prior art, the beneficial effects of this application are as follows: (1) The working roller pre-swirl guide and gradient cooling centrifugal composite device provided in this application can improve the matching relationship between the liquid metal inflow velocity and the linear velocity of the inner wall of the cold mold, reduce the relative impact when the liquid metal enters the cold mold, and help reduce splashing, air entrapment and turbulence, thereby improving the filling stability. The device of this application, by oriented the lateral tangential discharge port toward the rotation direction of the cold mold, makes the liquid metal have an initial tangential velocity component in the same direction as the rotation direction of the cold mold when it enters the cold mold, reducing the splashing and turbulence problems caused by the random direction of the traditional gate, and making the filling of the liquid metal more stable.
[0018] (2) The working roll pre-swirl guide and gradient controlled cooling centrifugal composite equipment provided in this application can make the temperature uniform and controllable, reducing casting defects caused by uneven cooling. This application, through the zoned arrangement of layered cooling pipelines and cooling medium nozzles, enables the cooling medium flow rate to be independently adjusted according to the region, avoiding excessive cooling in some areas, which can lead to overcooling, increased microstructure gradient, thermal stress concentration, or cracking tendency. At the same time, it avoids insufficient cooling in some areas, which can lead to coarse microstructure, shrinkage porosity, and increased segregation. The overall microstructure of the casting is more uniform and dense, and the differences in mechanical properties such as hardness and strength between different regions are reduced.
[0019] (3) This application improves the stability of the centrifugal composite process by using the synergistic effect of pre-spinning guiding pouring and zoned gradient cooling, and reduces forming defects caused by unstable filling and uneven cooling, thereby improving product quality stability and production qualification rate. It is especially suitable for centrifugal composite forming of large, high alloy composite work rolls. Attached Figure Description
[0020] Figure 1 This is a schematic diagram of the overall structure of the working roller pre-swirl guiding and gradient controlled cooling centrifugal composite device of this application; Figure 2This is a schematic diagram of the overall structure of the pre-swirl guiding casting system of this application; Figure 3 This is a schematic diagram of the flow channel guide section structure of this application; Figure 4 This is a schematic diagram of the exploded structure of the flow channel guide section of this application; Figure 5 This is a schematic diagram of the lateral tangential lead-out segment structure of this application; Figure 6 This is a schematic diagram of the exploded structure of the lateral tangential lead-out section of this application; Figure 7 This is a schematic diagram of the multi-stage tangential guide vane group of this application for graded flow guidance; Figure 8 This is a schematic diagram showing the relationship between the liquid discharge direction of the lateral tangential discharge port and the rotational tangent direction of the inner wall of the horizontal cooling structure. Figure 9 This is a schematic diagram showing multiple tilt angles of the guide vane formed between the guide vane and the axial direction of the lateral tangential outlet section of this application. Figure 10 This is a schematic diagram of the overall structure of the gradient cooling system of this application; Figure 11 This is a side view of the gradient cooling system of this application.
[0021] The main reference numerals are as follows: 1. Pre-swirling guide casting system; 11. Feed funnel; 12. Flow channel guide section; 121. First top plate; 122. First bottom plate; 123. First guide side plate; 124. Second guide side plate; 13. Lateral tangential outlet section; 131. Second top plate; 132. Second bottom plate; 133. First outlet side plate; 134. Second outlet side plate; 135. Flow stabilizing buffer chamber; 136. Multi-stage tangential guide plate assembly; 1361. Guide plate; 137. End sealing plate; 138. Opposed guide limiting plate assembly; 1381. Upper guide limiting plate; 1382. Lower... 14. Flow guide and limiting plate; 141. Bottom support; 141. Support trolley; 2. Horizontal cooling structure; 3. Gradient cooling system; 31. Support frame; 32. Layered cooling pipeline; 321. First layer cooling pipeline; 322. Second layer cooling pipeline; 33. Cooling medium nozzle; 331. Spray direction; 332. Tangential direction; 333. Cooling rotation direction; 34. Flow regulating valve; 35. Water pump; 36. Water tank; 37. Hose; 38. System main water inlet pipe; 39. Suction pipe; 4. Centrifugal composite system; 41. Double support roller system; 42. Drive unit. Detailed Implementation
[0022] Hereinafter, embodiments of the present application will be described with reference to the accompanying drawings.
[0023] The technical solution of this application will be further described below with reference to the accompanying drawings. It should be understood that the following embodiments are only used to explain this application and are not intended to limit the scope of protection of this application. Without departing from the concept of this application, those skilled in the art can make adaptive adjustments to the specific structural form, size proportions and connection methods.
[0024] like Figure 1 As shown in the figure, this embodiment provides a centrifugal composite device for pre-swirl guiding and gradient cooling of working rolls, including a pre-swirl guiding casting system 1, a gradient cooling system 3, and a centrifugal composite system 4. The centrifugal composite system 4 includes a horizontal cooling structure 2, a double-support roller system 41, and a drive unit 42. The double-support roller system 41 supports the horizontal cooling structure 2, and the drive unit 42 is connected to the double-support roller system 41 for transmission. The horizontal cooling structure 2 is supported by the double-support roller system 41 and rotates around its own axis under the action of the drive unit 42. An end-limiting structure for restricting the axial flow of liquid metal can be provided at the end of the horizontal cooling structure 2; the specific form of the end-limiting structure can be determined according to the size of the working roll and the casting process. The pre-swirl guiding casting system 1 is located at the feed end of the horizontal cooling structure 2 and is used to guide liquid metal into the horizontal cooling structure 2; the gradient cooling system 3 is located on the outside of the horizontal cooling structure 2 and is used for zoned gradient cooling of the forming process.
[0025] like Figure 2 and Figure 3 As shown, the pre-swirl guiding casting system 1 includes a feed funnel 11, a flow channel guiding section 12, a lateral tangential discharge section 13, and a bottom support 14. The feed funnel 11 is connected to the feed end of the flow channel guiding section 12, and the lateral tangential discharge section 13 is connected to the discharge end of the flow channel guiding section 12. The bottom support 14 is used to support and position the flow channel guiding section 12 and the lateral tangential discharge section 13. The bottom support 14 includes a support trolley 141, on which the flow channel guiding section 12 and the lateral tangential discharge section 13 are mounted. The support trolley 141 carries the pre-swirl guiding casting system 1 and adjusts the position of the lateral tangential discharge section 13 relative to the horizontal cold-form structure 2 before casting. The feed funnel 11 is used to receive liquid metal and guide it into the flow channel guide section 12; the flow channel guide section 12 is used to constrain and guide the liquid metal and stabilize its flow; the lateral tangential outlet section 13 is used to convert the liquid metal flowing along the flow channel guide section 12 into a lateral tangential outlet corresponding to the rotation direction of the horizontal cold structure 2.
[0026] like Figure 3 and Figure 4As shown, the flow channel guide section 12 includes a first top plate 121, a first bottom plate 122, a first flow guide side plate 123, and a second flow guide side plate 124. The first top plate 121, the first bottom plate 122, the first flow guide side plate 123, and the second flow guide side plate 124 enclose a flow channel for the flow of liquid metal. The first top plate 121 is disposed above the flow channel to limit the upward movement and splashing of liquid metal during the conveying process; the first flow guide side plate 123 and the second flow guide side plate 124 are disposed on both sides to limit the lateral diffusion of liquid metal; the first bottom plate 122 is used to support and guide the liquid metal to flow axially.
[0027] The first top plate 121, the first bottom plate 122, the first guide side plate 123, and the second guide side plate 124 are fixedly connected by welding to form an integrally formed flow channel 12, thereby creating a flow channel for the flow of liquid metal. The flow channel 12 can be installed in a forward or mirror manner according to the rotation direction of the horizontal cooling structure 2, so that the discharge direction of the flow channel 12 is adapted to the feed direction of the lateral tangential discharge section 13.
[0028] like Figures 5 to 7 As shown, the lateral tangential outlet section 13 includes a second top plate 131, a second bottom plate 132, a first outlet side plate 133, a second outlet side plate 134, and an end sealing plate 137. The second top plate 131, the second bottom plate 132, the first outlet side plate 133, and the second outlet side plate 134 enclose a flow stabilizing buffer cavity 135. The end sealing plate 137 is disposed at the axial end of the flow stabilizing buffer cavity 135 to close the axial end of the flow stabilizing buffer cavity 135, thereby preventing the liquid metal from continuing to rush forward in the original axial direction, so that the liquid metal forms a buffered and stabilizing flow area within the flow stabilizing buffer cavity 135.
[0029] The end cap 137 forms an inclined guide surface on the side facing the flow stabilizing buffer chamber 135, and the inclined guide surface is inclined relative to the axial direction of the lateral tangential outlet section 13. The extension direction of the inclined guide surface and the axial direction of the lateral tangential outlet section 13 form an end cap inclination angle γ, which is 10° to 45°.
[0030] The flow stabilizing buffer chamber 135 is equipped with an opposing flow guiding and limiting plate assembly 138, which includes an upper flow guiding and limiting plate 1381 and a lower flow guiding and limiting plate 1382 arranged relatively parallel to each other, forming a flow-limiting and guiding channel between the upper flow guiding and limiting plate 1381 and the lower flow guiding and limiting plate 1382. After the liquid metal enters the flow stabilizing buffer chamber 135, it flows axially along the flow-limiting and guiding channel, reducing the turbulence and free diffusion of the liquid metal in the vertical direction.
[0031] like Figure 7As shown, a multi-stage tangential guide plate assembly 136 is also provided within the flow stabilization buffer chamber 135. The multi-stage tangential guide plate assembly 136 includes several guide plates 1361 arranged at intervals. In specific applications, the multi-stage tangential guide plate assembly 136 includes at least two guide plates 1361. Each guide plate 1361 is arranged at intervals along the flow direction of the liquid metal. The guiding surface of the guide plate 1361 is inclined towards the lateral tangential discharge port provided on the first outlet side plate 133 or the second outlet side plate 134, so that the liquid metal changes its flow direction step by step when passing through the diversion channel. A diversion channel is formed between adjacent guide plates 1361, and the liquid metal undergoes directional deflection step by step when passing through the diversion channel, gradually changing from axial flow to lateral tangential flow. The horizontal spacing between adjacent guide plates 1361 along the flow direction of the liquid metal is... Decreasing according to an arithmetic progression: ; in, The horizontal spacing between the i-th adjacent guide vanes This refers to the horizontal spacing of the first level. The spacing decreases in increments, i = 1, 2, ..., n-1, where n is the total number of guide vanes, and >0.
[0032] like Figure 9 As shown, in the multi-stage tangential guide vane assembly 136, each guide vane 1361 forms a guide vane inclination angle with the axial direction of the lateral tangential outlet section 13. The inclination angle of each guide vane 1361 increases progressively along the liquid metal flow direction and satisfies: 10° ≤ < <...< <...< ≤30°, so that the liquid metal gradually transitions from axial flow to lateral tangential flow, wherein, Let be the inclination angle of the j-th guide vane, where j = 1, 2, ..., n, and n is the total number of guide vanes. Each branch channel formed between adjacent guide vanes 1361 creates a liquid metal outflow direction at the outlet. The outflow angle of the branch channel is formed between the liquid metal outflow direction and the axial direction of the lateral tangential outlet section. The outflow angle of the h-th branch channel is denoted as . h=1,2,...,n-1, and the total number of diversion channels formed between adjacent guide vanes is n-1. The range is from 10° to 45°. Figure 9 The tilt angle is shown in the figure. arrive Outflow angle arrive .
[0033] like Figure 8As shown, a lateral tangential discharge port is provided on one of the first outlet side plate 133 or the second outlet side plate 134, and is connected to the flow-limiting guide channel. The lateral tangential discharge port is set corresponding to the pouring point of the horizontal cold forming structure 2, and the liquid discharge direction of the lateral tangential discharge port corresponds to the rotational tangential direction of the inner wall of the horizontal cold forming structure 2 at the pouring point. With the above arrangement, when the liquid metal enters the horizontal cold forming structure 2 through the lateral tangential discharge port, it can obtain an initial tangential velocity component that is consistent with or approximately consistent with the cold forming rotation direction 333. The liquid discharge direction of the lateral tangential discharge port and the rotational tangential direction of the inner wall of the horizontal cold forming structure 2 at the pouring point form a tangential matching angle. Tangential matching angle The angle is 0° to 30°, preferably 15° to 30°. A transition guide surface is provided on the side of the second base plate 132 near the lateral tangential discharge port. The transition guide surface is used to guide the liquid metal to smoothly change from axial flow to lateral tangential flow. In a specific embodiment, the lateral tangential discharge port is a rectangular opening.
[0034] like Figure 10 As shown, the gradient cooling system 3 includes a support frame 31, layered cooling pipes 32, cooling medium nozzles 33, flow regulating valves 34, and a cooling medium supply unit. The cooling medium supply unit includes a water pump 35, a water tank 36, a hose 37, a system main inlet pipe 38, and a suction pipe 39. The support frame 31 is a vertical steel support frame. The outlet of the water tank 36 is connected to the inlet of the water pump 35 through the suction pipe 39. The outlet of the water pump 35 is connected to the system main inlet pipe 38. The system main inlet pipe 38 is connected to the first layer cooling pipe 321 and the second layer cooling pipe 322 via the flow regulating valve 34.
[0035] The tiered cooling pipes 32 have two or more layers, with each layer arranged along the height of the supporting frame 31. Cooling medium nozzles 33 are connected to the corresponding tiered cooling pipes 32 via hoses 37. The water pump 35 pressurizes the coolant in the water tank 36 and delivers it to the system's main water inlet pipe 38. The coolant is then distributed to each tiered cooling pipe 32 via a flow regulating valve 34, and then enters the cooling medium nozzles 33 via hoses 37 and is sprayed onto the horizontal cooling structure 2.
[0036] The flow rate of each layer of cooling pipe 32 is independently controlled. Flow regulating valves 34 are used to adjust the flow rate of the cooling medium in each layer of cooling pipe 32 to achieve zoned gradient cooling control in the centrifugal composite forming process. By adjusting the flow regulating valves 34 corresponding to each layer of cooling pipe 32, different circumferential spray positions can have different cooling intensities. By partially overlapping the spray coverage areas of adjacent cooling medium nozzles 33, the uniformity of axial spray coverage of the horizontal cold-formed structure 2 can be improved. This gradient cooling control system 3 can work in conjunction with the pre-swirl guiding casting system 1 to enable the liquid metal to complete centrifugal composite forming under stable filling and uniform cooling conditions. The cooling medium nozzles 33 are located on both sides of the horizontal cold-formed structure 2 and face the outer surface of the horizontal cold-formed structure 2. The outer surface of the horizontal cold-formed structure 2 refers to the outer circumferential surface of the horizontal cold-formed structure 2. In a radial section perpendicular to the axis of the horizontal cooling structure 2, the spray direction 331 of each cooling medium nozzle 33 is consistent with the rotational tangent direction 332 of the outer surface of the horizontal cooling structure 2 at the corresponding spray point, or a spray matching angle θ is formed between them, with the spray matching angle θ ranging from 0° to 30°, so that the cooling medium is sprayed onto the outer circular surface of the horizontal cooling structure along the rotation direction of the horizontal cooling structure. Through this arrangement, the cooling medium can be sprayed onto the outer circular surface along the rotation direction of the horizontal cooling structure 2, reducing local rebound and discontinuous spray coverage caused by the radial direct impact of the cooling medium, and improving the spreading continuity of the cooling medium on the outer circular surface of the horizontal cooling structure.
[0037] On the other hand, this application also provides a centrifugal composite forming method for a centrifugal composite device for pre-spinning and guiding flow of work rolls and gradient controlled cooling, comprising the following steps: S1. Equipment Adjustment: Set the pre-swirl guiding pouring system 1 at the feed end of the horizontal cold-formed structure 2, and adjust the position of the lateral tangential discharge port so that the liquid discharge direction of the lateral tangential discharge port corresponds to the rotation tangential direction of the inner wall of the horizontal cold-formed structure 2 at the pouring point.
[0038] S2. Adjust the horizontal cold-formed structure 2: Start the drive unit 42, and drive the horizontal cold-formed structure 2 to rotate around its axis through the double support roller system 41, so that the horizontal cold-formed structure 2 reaches the preset centrifugal composite speed.
[0039] S3, Pre-swirl guiding pouring: Liquid metal is injected into the flow channel guiding section 12 through the feed funnel 11. After being stably guided by the flow channel guiding section 12, the liquid metal enters the lateral tangential discharge section 13. Under the combined action of the flow stabilizing buffer chamber 135, the end sealing plate 137, the opposed flow guiding and limiting plate group 138 and the multi-stage tangential flow guiding plate group 136, the axial flow gradually changes to lateral tangential flow. Then, it enters the horizontal cold structure 2 through the lateral tangential discharge port.
[0040] When liquid metal enters the horizontal cooling structure 2 through the lateral tangential outlet, the relationship between the tangential velocity component of the liquid metal and the linear velocity of the inner wall of the horizontal cooling structure 2 satisfies: ; In the formula, The pre-spin velocity matching coefficient is... The velocity at which liquid metal flows out tangentially from the side outlet. The tangential matching angle is between the liquid discharge direction of the lateral tangential outlet and the rotational tangential direction of the inner wall of the horizontal cold-form structure 2 at the pouring point. For the cold type of angular velocity, The inner radius is for the cold-type. Preferably... The value ranges from 0.8 to 1.2. This is achieved by controlling the pre-spinning speed matching coefficient. Approaching 1 allows the tangential velocity component of the liquid metal entering the cold mold to match the linear velocity of the inner wall of the cold mold, thereby reducing liquid flow impact and turbulence.
[0041] S4. Centrifugal Composite Forming: The liquid metal entering the horizontal cold-form structure 2 adheres to the inner wall of the horizontal cold-form structure 2 under the action of centrifugal force and spreads circumferentially to form the outer layer of liquid metal on the working roll. After the outer layer of liquid metal on the working roll reaches the preset composite process state, the core liquid metal is introduced according to the forming process of the composite working roll, so that the core liquid metal and the outer layer of liquid metal on the working roll form a composite interface.
[0042] S5. Gradient controlled cooling solidification: Start the gradient controlled cooling system, adjust the flow rate of the cooling medium in each layer of cooling pipes through the flow regulating valve, and spray the cooling medium onto the outer surface of the horizontal cooling structure through the cooling medium nozzle, so that the molten metal solidifies and forms under the zoned gradient controlled cooling conditions.
[0043] The cooling medium flow rate of each layer of cooling pipes is distributed according to a preset gradient coefficient, and the relationship satisfies: ; In the formula, Let r be the flow rate of the cooling medium in the r-th layer of cooling pipes. Based on the cooling medium flow rate, This represents the gradient adjustment coefficient corresponding to the r-th layer of cooling pipes; by setting different... The value allows for different cooling intensities at different circumferential spray positions, thus achieving phased gradient cooling.
[0044] The embodiments described above are merely preferred embodiments of this application and are not intended to limit the scope of this application. Any modifications and improvements made by those skilled in the art to the technical solutions of this application without departing from the spirit of this application should fall within the protection scope defined by the claims of this application.
Claims
1. A composite device for working roller pre-swirl guiding and gradient controlled cooling centrifugal flow, characterized in that: It includes a pre-swirl guiding casting system, a gradient cooling system, and a centrifugal composite system. The centrifugal composite system includes a horizontal cooling structure, a double support roller system, and a drive unit. The horizontal cooling structure is cylindrical, the double support roller system is used to support the horizontal cooling structure, and the drive unit is connected to the double support roller system for transmission. The pre-swirl guiding and casting system is set at the feed end of the horizontal cold-form structure. The pre-swirl guiding and casting system includes a feed hopper, a flow channel guiding section, a lateral tangential discharge section and a bottom support. The feed hopper is connected to the feed end of the flow channel guiding section, the lateral tangential discharge section is connected to the discharge end of the flow channel guiding section, and the bottom support is used to support and position the flow channel guiding section and the lateral tangential discharge section. The flow channel guide section includes a first top plate, a first bottom plate, a first flow guide side plate, and a second flow guide side plate. The first top plate, the first bottom plate, the first flow guide side plate, and the second flow guide side plate enclose and form a flow channel for the flow of liquid metal. The lateral tangential discharge section includes a second top plate, a second bottom plate, a first discharge side plate, a second discharge side plate, and an end sealing plate. The second top plate, the second bottom plate, the first discharge side plate, and the second discharge side plate enclose a flow stabilizing buffer cavity. A lateral tangential discharge port is provided on the first discharge side plate or the second discharge side plate. The flow stabilizing buffer chamber is equipped with opposing flow guiding and limiting plate groups and multi-stage tangential flow guiding plate groups. The opposing flow guiding and limiting plate groups include upper and lower flow guiding and limiting plates arranged opposite each other, forming a flow limiting and guiding channel that communicates with the lateral tangential discharge port between the upper and lower flow guiding and limiting plates. The multi-stage tangential flow guiding plate groups include several spaced-apart flow guiding plates, with the flow guiding surface of the flow guiding plates inclined toward the lateral tangential discharge port. The liquid discharge direction of the lateral tangential discharge port corresponds to the rotational tangential direction of the inner wall of the horizontal cold-formed structure at the casting point. The gradient cooling system includes a support frame, layered cooling pipes, cooling medium nozzles, flow regulating valves, and a cooling medium supply unit.
2. The composite device for pre-spinning and guiding flow of the working roller and gradient controlled cooling centrifugal flow according to claim 1, characterized in that: The first top plate, the first bottom plate, the first guide side plate, and the second guide side plate are fixedly connected by welding to form an integral flow channel guide section; the flow channel guide section can be set up in a forward installation or mirror installation method according to the rotation direction of the horizontal cold-formed structure.
3. The composite device for pre-spinning and guiding flow of the working roller and gradient controlled cooling centrifugal flow according to claim 1, characterized in that: The second bottom plate has a transition guide surface on the side near the lateral tangential discharge port. The transition guide surface is used to guide the liquid metal from axial flow to lateral tangential flow. The lateral tangential discharge port is rectangular. The end sealing plate is set at the axial end of the flow stabilizing buffer chamber. The side of the end sealing plate facing the flow stabilizing buffer chamber forms an inclined guide surface. The inclined guide surface and the axial direction of the lateral tangential discharge section form an inclination angle γ of the end sealing plate, which is 10° to 45°.
4. The composite device for pre-swirl guiding and gradient controlled cooling centrifugal flow of the working roller according to claim 1, characterized in that: The upper flow guide limiting plate and the lower flow guide limiting plate are set in parallel.
5. The composite device for pre-swirl guiding and gradient controlled cooling centrifugal flow of the working roller according to claim 1, characterized in that: The multi-stage tangential guide plate assembly includes at least two guide plates, which are arranged at intervals along the flow direction of the liquid metal, and a flow-dividing channel is formed between adjacent guide plates; the multi-stage tangential guide plate assembly realizes the step-by-step flow guidance of liquid metal by changing the spacing between adjacent guide plates or changing the tilt angle of each guide plate; Horizontal spacing between adjacent guide vanes along the direction of liquid metal flow Decreasing according to an arithmetic progression, satisfying: ； in, The horizontal spacing between the i-th adjacent guide vanes This refers to the horizontal spacing of the first level. The spacing decreases in increments, i = 1, 2, ..., n-1, where n is the total number of guide vanes, and >
0.
6. The composite device for pre-spinning and guiding flow of the working roller and gradient controlled cooling centrifugal flow according to claim 5, characterized in that: Each guide vane forms a guide vane inclination angle with the axial direction of the lateral tangential outlet section. The inclination angle of each guide vane increases progressively along the direction of liquid metal flow and satisfies: 10° ≤ < <...< <...< ≤30°, so that the liquid metal gradually transitions from axial flow to lateral tangential flow, wherein, Let be the inclination angle of the j-th guide vane, where j = 1, 2, ..., n, and n is the total number of guide vanes. Each branch channel formed between adjacent guide vanes creates a liquid metal outflow direction at the outlet. The outflow angle of the branch channel is formed between the liquid metal outflow direction and the axial direction of the lateral tangential outlet section. The outflow angle of the h-th branch channel is denoted as . h=1,2,...,n-1, and the total number of diversion channels is n-1. The range is from 10° to 45°.
7. The composite device for pre-spinning and guiding flow of the working roller and gradient controlled cooling centrifugal flow according to claim 1, characterized in that: The liquid discharge direction of the lateral tangential outlet forms a tangential matching angle with the rotational tangential direction of the inner wall of the horizontal cold-formed structure at the casting point. Tangential matching angle The range is from 0° to 30°.
8. The composite device for pre-spinning and guiding flow of the working roller and gradient controlled cooling centrifugal flow according to claim 1, characterized in that: The number of layers of the stratified cooling pipeline is two or more. Each layer of the stratified cooling pipeline is arranged along the height of the supporting frame. The cooling medium nozzles are connected to the stratified cooling pipeline and are set towards the outer surface of the horizontal cooling structure. The flow rate of each layer of the stratified cooling pipeline is independently controlled.
9. The composite device for pre-swirl guiding and gradient controlled cooling centrifugal flow of the working roller according to claim 1, characterized in that: The flow regulating valve is used to regulate the flow rate of the cooling medium in each layer of the cooling pipe to achieve zoned gradient controlled cooling in the centrifugal composite forming process. The cooling medium nozzles are set on both sides of the horizontal cooling structure. The spray direction of each cooling medium nozzle is consistent with the rotational tangent direction of the outer surface of the horizontal cooling structure at the corresponding spray point or forms a spray matching angle θ, which is 0° to 30°.
10. A centrifugal composite forming method using the centrifugal composite equipment for pre-spinning and guiding flow of the working roller and gradient controlled cooling as described in any one of claims 1 to 9, characterized in that: It includes the following steps: S1. Equipment adjustment: Set the pre-swirl guiding pouring system at the feed end of the horizontal cold-formed structure, and adjust the position of the lateral tangential discharge port so that the liquid discharge direction of the lateral tangential discharge port corresponds to the rotation tangential direction of the inner wall of the horizontal cold-formed structure at the pouring point. S2. Adjust the horizontal cold-formed structure: Start the drive unit and drive the horizontal cold-formed structure to rotate around its axis through the double support roller system, so that the horizontal cold-formed structure reaches the preset centrifugal composite speed. S3, Pre-swirl guiding pouring: Liquid metal is injected into the flow channel guide section through the feed funnel. After being guided by the flow channel guide section, the liquid metal enters the lateral tangential discharge section. Under the combined action of the flow stabilizing buffer chamber, end sealing plate, opposed flow limiting plate group and multi-stage tangential flow guiding plate group, the axial flow gradually changes to lateral tangential flow. Then, it enters the horizontal cold mold structure through the lateral tangential discharge port. When liquid metal enters the horizontal cooling structure through the lateral tangential outlet, the relationship between the tangential velocity component of the liquid metal and the linear velocity of the inner wall of the horizontal cooling structure satisfies: ； In the formula, The pre-spin velocity matching coefficient, The velocity at which liquid metal flows out tangentially from the side outlet. The tangential matching angle is the direction of liquid discharge from the lateral tangential outlet and the direction of rotational tangential of the inner wall of the horizontal cold-formed structure at the pouring point. For the cold type of angular velocity, The inner radius of the cold type; by controlling the pre-spinning speed matching coefficient To control the relationship between the tangential velocity component of the liquid metal and the linear velocity of the inner wall of the horizontal cold-formed structure; S4. Centrifugal composite forming: The liquid metal entering the horizontal cold forming structure adheres to the inner wall of the horizontal cold forming structure under the action of centrifugal force and spreads along the circumference to form the outer layer of liquid metal of the working roller; after the outer layer of liquid metal of the working roller reaches the preset composite process state, the core liquid metal is introduced so that the core liquid metal and the outer layer of liquid metal of the working roller form a composite interface. S5. Gradient controlled cooling solidification: Start the gradient controlled cooling system, adjust the flow rate of the cooling medium in each layer of cooling pipes through the flow regulating valve, and spray the cooling medium onto the outer surface of the horizontal cooling structure through the cooling medium nozzle, so that the molten metal solidifies and forms under the zoned gradient controlled cooling conditions. The cooling medium flow rate of each layer of cooling pipes is distributed according to a preset gradient coefficient, and the relationship satisfies: ； In the formula, Let r be the flow rate of the cooling medium in the r-th layer of cooling pipes. Based on the cooling medium flow rate, This represents the gradient adjustment coefficient corresponding to the r-th layer of cooling pipes; by setting different... value.