Permanent Mold Cooling Channel Layout for Uniform Heat Dissipation
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Solution Overview
Problem
Existing continuous casting permanent molds face challenges in achieving a cooling effect that is uniformly adjusted to different zones, particularly at high thermal stress areas, leading to potential overheating and uneven heat distribution.
Innovation Solution
The design incorporates cooling channels with varying longitudinal sections and alignments within the mold body, allowing for a horizontally and vertically adjusted cooling effect by bringing the cooling medium closer to the casting surface in high-thermal zones, thereby optimizing cooling performance and preventing overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling lines are positioned closer to the casting surface in high-thermal zones, then cooling effect in thermally stressed regions is improved, but device complexity increases due to varying channel alignments
Solution Approach 1:
The patent applies local quality by varying the distance of cooling channels from the casting surface according to the thermal weighting profile of different mold zones. In high-thermal zones, cooling channels are positioned closer to the casting surface, while in low-thermal zones, they are positioned farther away. This creates a non-uniform cooling channel arrangement that matches the local thermal requirements of each mold region, optimizing cooling efficiency without unnecessary complexity.
Solution Approach 2:
The patent transitions from uniform cooling channel alignment to multi-aligned cooling channels with different longitudinal axis orientations. By introducing angular variations in channel alignments and using bent channel courses, the system adds dimensional complexity to the channel arrangement, enabling three-dimensional optimization of cooling coverage across the mold body's thermal profile.
2Ease of manufacture
If cooling channels are uniformly distributed, then manufacturing simplicity is maintained, but cooling performance in high-thermal zones is insufficient
Solution Approach 1:
The patent implements local quality by creating zones with different cooling channel densities and alignments corresponding to the thermal weighting profile. High-thermal zones receive enhanced cooling with channels positioned closer to the casting surface and potentially with multiple alignments, while low-thermal zones have fewer or more remotely positioned channels. This localized optimization improves heat dissipation efficiency without requiring complete redesign of the entire cooling system.
Solution Approach 2:
The patent introduces dynamic adaptability in the cooling channel configuration by incorporating bent courses and multiple longitudinal section alignments. The cooling channels follow curved paths and change directions to adapt to the varying thermal requirements along the mold body, allowing the static structure to dynamically respond to thermal gradients through its geometric design.
3Temperature
If cooling lines are positioned closer to the casting surface, then heat dissipation in critical zones is improved, but risk of vaporization increases
Solution Approach 1:
The patent applies local quality by positioning cooling channels at optimally different distances from the casting surface based on local thermal weighting. In high-thermal zones where heat removal is critical, channels are positioned closer to enhance cooling. In regions with lower thermal weighting, channels are positioned farther away, reducing the risk of vaporization and maintaining cooling medium stability. This spatial variation balances heat removal efficiency with operational reliability.
4Stability of the object's composition
If multiple cooling zones with different cooling effects are implemented, then temperature distribution uniformity is improved, but device complexity increases
Solution Approach 1:
The patent implements local quality by creating multiple cooling zones with differentiated channel alignments and distances from the casting surface. Each zone is designed with specific channel configurations matched to its thermal weighting, resulting in localized cooling effects that collectively achieve uniform temperature distribution across the entire mold body.
Solution Approach 2:
The patent segments the cooling system into multiple zones with distinct cooling characteristics. By dividing the mold body into regions with different thermal weightings and assigning appropriate cooling channel configurations to each region, the system achieves comprehensive temperature control through segmented, zone-specific cooling strategies.
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 ensures effective heat dissipation, maintains the copper alloy's recrystallization temperature, avoids vaporization, and achieves uniform heat distribution across the mold height, enhancing the cooling performance in thermally stressed regions.
Implementation Method 1
The permanent mold body is cooled because, above all, at high casting speeds, there is a danger that, in this context, on a local basis, the permissible thermal load of the permanent mold material is exceeded
Implementation Method 2
a continuous casting permanent mold is a part of the related art whose form wall is furnished with continuous cylindrical cooling water lines connected to a cooling water circulation
Data Source
AI summary
A liquid-cooled permanent mold for a continuous casting installation having a shaping permanent mold body, for example, made of copper or copper alloy. Cooling channels are provided in permanent mold body that extend from its upper side to its lower side. The cooling channels each have two longitudinal sections and the cooling sections have an alignment of their longitudinal axes that differ from one another. In this way, the horizontal distance of the cooling channels from the casting surface is varied and a cooling performance is achieved that is adjusted to the weighting profile of the permanent mold.