Continuous Casting Mold Additive Structure
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Solution Overview
Problem
Existing molds for continuous steel casting face issues with wall rigidity due to thin thickness and water pressure, leading to bending, which is inadequately addressed by traditional connecting ribs and grooves, resulting in incomplete prevention of mold deformation.
Innovation Solution
The use of generative manufacturing processes like three-dimensional printing or selective laser melting to create a structure with optimally designed connecting elements on the outer jacket of the mold, enhancing heat transfer and supporting the thin wall, allowing for a one-piece production of the mold, tube, and casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the pipe wall is made thin to improve heat transfer efficiency, then heat transfer performance is improved, but the pipe wall rigidity deteriorates and bending occurs under water pressure
Solution Approach 1:
The mold tube is divided into multiple sections along its length, with connecting ribs formed between sections to create integrated cooling channels. This segmentation allows the thin-walled sections to maintain structural integrity while preserving heat transfer efficiency, as the ribs provide reinforcement without significantly impeding thermal conduction.
Solution Approach 2:
The mold structure combines the thin-walled copper tube with the support jacket and connecting ribs to create a composite structure. The copper tube provides excellent thermal conductivity for heat transfer, while the support jacket and ribs provide mechanical strength and rigidity to prevent bending under water pressure.
2Strength
If connecting ribs are added to prevent bending, then structural support is improved, but the complexity of manufacturing increases
Solution Approach 1:
The connecting ribs are merged with the cooling channels, forming an integrated structure where the ribs serve dual functions: providing structural support to prevent tube bending and forming the walls of the cooling channels for water circulation. This eliminates the need for separate cooling channel components, simplifying manufacturing.
Solution Approach 2:
The connecting ribs perform multiple functions simultaneously: they provide mechanical support to prevent tube deformation, form the cooling channel structure, and facilitate water circulation. This multi-functionality reduces the number of separate components needed, thereby reducing manufacturing complexity.
3Ease of operation
If tolerances are increased for rib insertion, then ease of assembly is improved, but the effectiveness in preventing tube bending decreases
Solution Approach 1:
The connecting ribs are formed as an integral part of the copper tube through additive manufacturing, eliminating the need for separate insertion and assembly operations. This merging of the rib structure with the tube body ensures precise geometric relationships while simplifying assembly to a single operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach improves the rigidity and heat transfer efficiency of the mold, maintaining homogeneous temperature distribution during casting and extending the mold's service life by optimizing the cooling geometry and support structure.
Implementation Method 1
The tube, the structure and the casing are produced in one piece by this additive manufacturing process
Implementation Method 2
the three-dimensional printing process, which is known per se, is particularly suitable and can be performed by selective laser melting (SLM) or laser sintering (SLS)
Implementation Method 3
a suitable temperature can be set on the inside of the mold with a sufficiently homogeneous distribution in the mold
Implementation Method 4
enhancing heat transfer and supporting the thin wall
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
In a method for manufacturing a mold for continuous casting of metallic products, a mold (10) is provided from a single-piece tube (11) or from several sections, preferably formed as mold plates. A structure (35) is produced on the tube (31) itself and/or at least on the outer and/or inner surfaces of the tube (31) or the sections by an additive manufacturing process. Connecting elements (36) for guiding a cooling medium are assigned to the outer surfaces of the tube (31) or the sections. By generating the structure with various mold configurations, a geometry optimally adapted to the casting conditions can be produced.