A composite gating system for preventing cracking of a ferrochrome ingot mold

Abstract

The utility model relates to ingot mould casting technical field especially relates to a kind of composite pouring system of anti-cracking chrome-iron ingot mould. First, second steel bar of longitudinal and transverse intersection is fixed in ingot mould, and form three-dimensional reinforcing structure, the first steel bar shaft center plane is the mold parting surface and located between second steel bar and mold cavity bottom surface, and steel bar both ends extend out of ingot mould to facilitate hoisting. Composite pouring system includes first, second pouring structure, riser and lifting ring;First pouring structure is bottom pouring structure, and send nodular cast iron molten iron by straight sprue, horizontal gate, ceramic tube and inner gate;Second pouring structure is side pouring structure, and send cupola cast iron molten iron by straight sprue, horizontal gate and inner gate;Riser is used for feeding, and lifting ring fixes steel bar position. The system can improve ingot mould crack resistance, reduce casting defects, realize material quality combination, prolong ingot mould life.

Description

Technical Field

[0001] This utility model relates to the field of ingot casting technology, and in particular to a composite casting system for anti-cracking ferrochrome ingot molds. Background Technology

[0002] In the field of metallurgical casting, ferrochrome ingot molds are the core molds used to support and shape ferrochrome ingots, and their quality directly affects the forming effect and production efficiency of ferrochrome ingots. With the increasing demands for mold lifespan and crack resistance in the ferrochrome smelting industry, the traditional production process of ferrochrome ingot molds has gradually revealed many problems. Traditional ingot molds are mostly cast from a single material, lacking effective structural reinforcement design inside. Under long-term exposure to the impact of high-temperature molten iron and alternating hot and cold cycles, they are prone to cracking due to internal stress concentration. This not only shortens the mold's lifespan but may also lead to defects in the ferrochrome ingot forming process, increasing production costs.

[0003] Meanwhile, traditional ingot casting systems mostly employ either bottom pouring or top pouring. While bottom pouring facilitates the floating of impurities, its slow filling speed makes it difficult to meet the high-efficiency casting requirements of large ingot molds. Top pouring, although fast, easily leads to molten iron splashing and turbulence, increasing the probability of casting defects such as oxide inclusions and affecting the overall quality of the ingot mold. If multiple materials are used for composite casting to optimize ingot mold performance, the mismatch between the filling methods of the two materials often results in poor interfacial bonding, leading to problems such as delamination and cracking, further limiting the improvement of ferrochrome ingot mold performance. Utility Model Content

[0004] To address the aforementioned technical problems, this utility model provides a composite casting system for anti-cracking ferrochrome ingot molds. By incorporating crisscrossing reinforcing steel bars inside the mold and employing a composite casting method combining bottom and side pouring, it solves the problems of traditional ferrochrome ingot molds being prone to cracking, having a short service life, and easily generating oxide inclusions during casting. Specifically, this is achieved through the following technical solutions: This utility model discloses a composite casting system for a crack-resistant ferrochrome ingot mold, comprising an ingot mold, wherein a first steel bar and a second steel bar arranged in a cross-sectional pattern in a plane are fixed inside the ingot mold to form a three-dimensional reinforced structure. The composite casting system also includes a first casting structure, a second casting structure, risers, and lifting rings; The first casting structure is a bottom-pouring structure, which includes a first sprue, a first horizontal sprue, a ceramic tube and a first ingate connected in sequence, for conveying molten ductile iron; The second pouring structure is a side pouring structure, which includes a second sprue, a second horizontal sprue and a second inner sprue connected in sequence, for conveying gray cast iron molten iron; The riser is located above the ingot mold for shrinkage compensation; The lifting ring is fixed to the first steel bar and is used to position the steel bar and assist in lifting.

[0005] Preferably, the first steel rods are evenly arranged parallel to the width direction of the ingot mold, and the second steel rods are evenly arranged parallel to the length direction of the ingot mold, with the outer surfaces of the first steel rods and the second steel rods in contact with each other.

[0006] Preferably, the plane containing the axis of the first steel rod is located between the plane containing the axis of the second steel rod and the bottom surface of the mold cavity, and serves as the mold parting surface.

[0007] Preferably, the two ends of the first and second steel bars extend 15-20 cm beyond the side of the ingot mold.

[0008] Preferably, the cross-sectional area ratio of the first sprue, the first gating system, and the first ingate is 58-70:30-36:12-13.

[0009] Preferably, the cross-sectional area ratio of the second sprue, the second runner, and the second ingate is 54-60:47-53:30-34.

[0010] Preferably, there are four ceramic tubes and four first ingates, and the axis of the first ingate is aligned vertically with the axis of the second steel bar located on the side.

[0011] Preferably, the number of the second ingate is 8, which are divided into two groups and arranged symmetrically about the center of the second sprue.

[0012] Preferably, there are 6 risers, located at the four corners and the middle of the ingot mold, and they are in the shape of an inverted frustum.

[0013] Preferably, the lifting ring includes an arc-shaped section, a vertical section, and a bent section. The arc-shaped section is wrapped around the outer surface of the first steel bar, and the bent section is fixed to the upper mold. Each first steel bar is provided with 3 lifting rings.

[0014] After adopting the above technical solution, the beneficial effects of this utility model are: 1. This utility model forms a three-dimensional reinforcing network by setting up a first steel bar and a second steel bar arranged in a cross pattern, which significantly enhances the overall rigidity and thermal stress resistance of the ingot mold and effectively prevents cracking and deformation caused by temperature changes during use.

[0015] 2. A composite casting method combining bottom pouring and side pouring is adopted. The bottom pouring part achieves stable filling and impurity floating, while the side pouring part achieves rapid feeding and temperature equalization, which together improves the uniformity and density of the ingot's internal quality.

[0016] 3. By pouring molten iron of different materials in stages, first pouring ductile iron at the bottom and then pouring gray cast iron at the side, the characteristics of the two are used to achieve interfacial metallurgical bonding, avoid oxidation and slag inclusions, and significantly improve the comprehensive mechanical properties and service life of the ingot mold.

[0017] 4. The design of the lifting ring structure not only facilitates mold closing and hoisting, but also accurately positions the pre-embedded steel bars during the pouring process, preventing them from shifting and ensuring the positional accuracy and structural consistency of the reinforced structure.

[0018] 5. The riser layout is scientific and the shape is reasonable, which enhances the feeding effect, reduces shrinkage cavities and porosity, and further improves the surface and internal quality of the finished ingot. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 A three-dimensional diagram of a ferrochrome ingot mold to prevent cracking; Figure 2 A first-person perspective perspective view of the composite casting system for preventing cracking of ferrochrome ingot molds; Figure 3 A second-view perspective perspective of the composite casting system for preventing cracking of ferrochrome ingot molds; Figure 4 A third-person perspective view of the composite casting system for preventing cracking of ferrochrome ingot molds; Figure 5 for Figure 2 A three-dimensional view of part of the structure.

[0021] Explanation of reference numerals in the attached figures: 101-Ingot mold, 102-Mold cavity, 103-First steel bar, 104-Second steel bar; 200-First casting structure, 201-First straight sprue, 202-First horizontal sprue, 203-Ceramic tube, 204-First inner sprue; 300 - Second casting structure, 301 - Second sprue, 302 - Second gating runner, 303 - Second ingate; 400 - riser, 500 - ring. Detailed Implementation

[0022] The features and exemplary embodiments of various aspects of this utility model will now be described in detail. To make the objectives, technical solutions, and advantages of this utility model clearer, the following description, in conjunction with the accompanying drawings and specific embodiments, will provide a further detailed description of this utility model. It should be understood that the specific embodiments described herein are only configured to explain this utility model and are not configured to limit this utility model. For those skilled in the art, this utility model can be implemented without certain specific details. The following description of the embodiments is merely intended to provide a better understanding of this utility model by illustrating examples of it.

[0023] The directional terms used in the following description refer to the directions shown in the figures and are not intended to limit the specific structure of this utility model. It should also be noted in the description of this utility model that, unless otherwise explicitly specified and limited, the terms "installation" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0024] An embodiment of this utility model provides a composite casting system for anti-cracking ferrochrome ingot molds. This casting system is used to complete the casting of ingot mold 101. See [link to documentation]. Figure 1 The upper surface of the ingot mold 101 is provided with a mold cavity 102 for casting ingot blocks. Several first steel bars 103 parallel to the width direction of the ingot mold 101 are fixed inside the ingot mold 101. The several first steel bars 103 are evenly distributed along the length direction of the ingot mold 101. The axes of the several first steel bars 103 are located in the same plane, which is parallel to the bottom surface of the ingot mold 101.

[0025] Inside the ingot mold 101, there are also a number of second steel bars 104 parallel to the length direction of the ingot mold 101. The number of second steel bars 104 are evenly distributed along the width direction of the ingot mold 101, and the axes of the number of second steel bars 104 are located in the same plane, which is parallel to the bottom surface of the ingot mold 101.

[0026] Preferably, there are two first steel bars 103 and three second steel bars 104.

[0027] The plane containing the axis of the first steel bar 103 is located between the plane containing the axis of the second steel bar 104 and the bottom surface of the mold cavity 102, and the plane containing the axis of the first steel bar 103 serves as the mold parting surface.

[0028] The outer surface of the first steel rod 103 is in contact with the outer surface of the second steel rod 104, and both end faces of the first steel rod 103 and the second steel rod 104 extend 15-20cm beyond the side of the ingot mold 101, which facilitates the hoisting of the ingot mold 101.

[0029] See Figures 2-5 To ensure the casting quality of the ingot mold, inverted casting is adopted, and a composite casting method combining bottom casting and side casting is used. The composite casting system includes a first casting structure 200, a second casting structure 300, a riser 400, and a lifting ring 500.

[0030] See Figure 2 , Figure 3 The first casting structure 200 includes a vertically arranged first sprue 201. The first sprue 201 is close to the side of one of the ingot molds 101 where the length and height are located. The bottom of the first sprue 201 is connected to the middle of the first horizontal sprue 202. The side of the first horizontal sprue 202 is connected to the first end of several ceramic tubes 203. The second end of the ceramic tubes 203 is connected to the first end of the first inner sprue 204. The second end of the first inner sprue 204 is connected to the ingot mold 101.

[0031] The ceramic tube 203 and the first ingate 204 are located directly below the ingot mold 101, and the inner diameter of the ceramic tube 203 is equal to the diameter of the first ingate 204.

[0032] The number of ceramic tubes 203 and first ingates 204 is equal, preferably four in each case. The axes of two of the first ingates 204 are aligned vertically with the axis of one of the second steel bars 104 located on the side, and the axes of the other two first ingates 204 are aligned vertically with the axis of the other second steel bar 104 located on the side.

[0033] The ratio of the cross-sectional areas of the first straight gating 201, the first horizontal gating 202, and the first inner gating 204 is 58-70:30-36:12-13.

[0034] The first pouring structure 200 is used for pouring the bottom pouring part of the ingot mold. During the pouring process, molten iron is first transported to the top of the first straight sprue 201 through the pouring cup. The molten iron enters the first horizontal sprue 202 through the first straight sprue 201 and is transported to the first inner sprue 204 through several ceramic tubes 203 on the side of the first horizontal sprue 202. Finally, it flows into the mold cavity through the first inner sprue 204. This bottom pouring method is conducive to the floating of impurities and avoids casting defects.

[0035] See Figure 4The second casting structure 300 includes a vertically arranged second sprue 301. The bottom of the second sprue 301 is connected to the middle of the second horizontal sprue 302. The side of the second horizontal sprue 302 is connected to the first end of a plurality of second ingates 303. The second end of the second ingates 303 is connected to the ingot mold 101.

[0036] The number of second ingates 303 is preferably eight, and they are divided into two groups, which are symmetrically arranged about the center of the second sprue 301.

[0037] The ratio of the cross-sectional areas of the second straight gating 301, the second horizontal gating 302, and the second ingate 303 is 54-60:47-53:30-34.

[0038] The second casting structure 300 is used for casting the side casting part of the ingot mold. During casting, the molten iron is first transported to the top of the second sprue 301 through the pouring cup. The molten iron enters the second horizontal sprue 302 through the second sprue 301 and is transported to the cavity through a number of second ingates 303 provided on the side of the second horizontal sprue 302.

[0039] See Figure 4 , Figure 5 A number of risers 400 are vertically arranged above the ingot mold 101 and connected to the ingot mold 101. The number of risers 400 is preferably 6, including 4 located at the four corners of the ingot mold 101 and 2 located in the middle of the ingot mold 101.

[0040] The riser 400 is designed as an inverted frustum shape to facilitate the feeding of the ingot mold 101 during the casting process.

[0041] The lifting ring 500 includes an arc segment, a vertical segment, and a bent segment, which are connected in sequence. The vertical segment is located between the arc segment and the bent segment. The arc segment of the lifting ring 500 is wrapped around the outer surface of the first steel bar 103, and the bent segment is fixed to the upper mold. Several lifting rings 500 are evenly distributed along the length direction of the first steel bar 103.

[0042] Preferably, each of the first steel bars 103 has three lifting rings 500.

[0043] With the above-described structure, the lifting ring 500 fixes the positions of the two first steel bars 103 by the upper mold before casting, preventing the first steel bars 103 from shifting during the casting process. In addition, since several second steel bars 104 are located above the first steel bars 103 during casting, the several second steel bars 104 are directly fixed and installed on the upper mold. After the mold is closed, a cavity with several first steel bars 103 and second steel bars 104 is formed. After casting is completed, the first steel bars 103, second steel bars 104 and part of the lifting ring 500 are contained inside the ingot mold 101. The first steel bars 103 and second steel bars 104, which intersect laterally and longitudinally, are used to improve the strength and stability of the ingot mold 101, which is beneficial to improving product quality and service life.

[0044] Among them, the first steel bar 103, the second steel bar 104 and the lifting ring 500 are all made of 20# steel. Surface treatment is required before pre-embedding to avoid rust and other impurities affecting the quality of the ingot mold 101.

[0045] During the casting process, the materials cast by the first casting structure 200 and the second casting structure 300 are different. The first casting structure 200 casts ductile iron, while the second casting structure 300 casts gray cast iron. During casting, molten ductile iron is first poured through the first casting structure 200, and the amount of ductile iron is controlled so that the upper liquid level in the cavity after casting is flush with the second ingate 303. At this time, molten gray cast iron is poured through the second casting structure 300 until casting is completed.

[0046] Using the above-mentioned casting method, because ductile iron contains spheroidizing elements such as magnesium and rare earth elements, it is extremely prone to oxidation and the formation of oxide inclusions in the molten state. These defects will seriously impair its mechanical properties. Bottom pouring method allows high-temperature molten iron to rise steadily from the bottom of the mold, achieving a splash-free and turbulent filling process, greatly reducing the contact between molten iron and air, thereby effectively preventing oxidation and the formation of inclusions.

[0047] Then, gray cast iron is poured in. Gray cast iron itself has good fluidity and casting properties and is not easily oxidized, which makes it suitable for rapid filling. Side pouring introduces molten iron into the middle of the cavity or at a specific height through multiple ingates. Its impact force is more gentle and controllable than top pouring, avoiding direct scouring and erosion of the bottom ductile iron surface. In addition, the rapid filling of gray cast iron brings concentrated heat, which can produce a local remelting effect on the solidified ductile iron surface, allowing sufficient element diffusion and metallurgical reaction to occur at the interface between the two metal layers, thereby forming a high-strength, defect-free metallurgical bond.

[0048] The embodiments described above are not exhaustive, nor do they limit the scope of the present invention to the specific embodiments described herein. Clearly, many modifications and variations can be made based on the above description. These embodiments are selected and specifically described in this specification to better explain the principles and practical applications of the present invention, thereby enabling those skilled in the art to effectively utilize the present invention and its modifications. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A composite casting system for a crack-resistant ferrochrome ingot mold, characterized in that, It includes a mold (101), in which a first steel bar (103) and a second steel bar (104) arranged in a cross direction in a horizontal plane are fixed inside the mold (101) to form a three-dimensional reinforced structure; The composite casting system also includes a first casting structure (200), a second casting structure (300), a riser (400), and a lifting ring (500). The first casting structure (200) is a bottom-pouring structure, including a first sprue (201), a first gating (202), a ceramic tube (203) and a first ingate (204) connected in sequence, for conveying molten ductile iron; The second casting structure (300) is a side-casting structure, including a second sprue (301), a second grate (302), and a second ingate (303) connected in sequence, for conveying gray cast iron molten iron; The riser (400) is located above the ingot mold (101) for feeding. The lifting ring (500) is fixed to the first steel bar (103) and is used to position the steel bar and assist in lifting.

2. The composite casting system according to claim 1, characterized in that: The first steel bar (103) is uniformly arranged parallel to the width direction of the ingot mold, and the second steel bar (104) is uniformly arranged parallel to the length direction of the ingot mold, and the outer surfaces of the first steel bar (103) and the second steel bar (104) are in contact with each other.

3. The composite casting system according to claim 2, characterized in that: The plane containing the axis of the first steel bar (103) is located between the plane containing the axis of the second steel bar (104) and the bottom surface of the mold cavity (102), and serves as the mold parting surface.

4. The composite casting system according to claim 1, characterized in that: The first steel bar (103) and the second steel bar (104) extend 15-20 cm from the side of the ingot mold.

5. The composite casting system according to claim 1, characterized in that: The cross-sectional area ratio of the first sprue (201), the first grate (202), and the first ingate (204) is 58-70:30-36:12-13.

6. The composite casting system according to claim 1, characterized in that: The cross-sectional area ratio of the second sprue (301), the second grate (302), and the second ingate (303) is 54-60:47-53:30-34.

7. The composite casting system according to claim 1, characterized in that: The number of ceramic tubes (203) and the number of first ingates (204) are both 4, and the axis of the first ingate (204) is aligned vertically with the axis of the second steel bar (104) located on the side.

8. The composite casting system according to claim 1, characterized in that: The number of the second ingate (303) is 8, which are divided into two groups and arranged symmetrically about the center of the second sprue (301).

9. The composite casting system according to claim 1, characterized in that: There are 6 risers (400), located at the four corners and the middle of the mold, and they are in the shape of an inverted frustum.

10. The composite casting system according to claim 1, characterized in that: The lifting ring (500) includes an arc segment, a vertical segment and a bent segment. The arc segment is wrapped around the outer surface of the first steel bar (103), and the bent segment is fixed to the upper mold. Each first steel bar (103) is provided with 3 lifting rings (500).

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