Offset Bore Casting Nozzle for H-Beam Mould Filling
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Solution Overview
Problem
Existing nozzles for casting complex metal beams, such as H-beams, face challenges in achieving stable and uniform metal flow, leading to increased production costs and defects due to the need for coordinated dual nozzles or limited size and design constraints of single nozzles, which result in uneven flow rates and turbulence.
Innovation Solution
A submerged nozzle design with an elongated portion and offset bore geometry, featuring a longer front port channel and distinct centroids for the bore and peripheral wall, allowing for enhanced stability and momentum dissipation, enabling smoother flow and thermal profiles in complex-shaped moulds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two nozzles are used for a single mould, then optimal filling of the mould and thermal profile are improved, but production costs increase and flow rate coordination becomes difficult
Solution Approach 1:
The single nozzle is segmented into multiple outlet openings (front ports) positioned at different locations and angles. This allows the nozzle to function like multiple nozzles by directing metal flow into different regions of the mould through strategically positioned front ports, achieving uniform filling without requiring multiple separate nozzle units
Solution Approach 2:
The single nozzle is designed to perform multiple functions that would traditionally require two separate nozzles. By incorporating multiple front ports with different orientations and positions, one nozzle unit can simultaneously address multiple filling requirements of the mould, reducing component count while maintaining filling quality
2Productivity
If nozzle size is increased to improve flow rate, then metal feeding capability is improved, but contact with mould walls increases causing solidified metal bridges
Solution Approach 1:
The nozzle design extends front ports in transverse directions perpendicular to the main flow axis, allowing the nozzle to reach into corner regions of the mould without increasing axial length. This dimensional approach enables adequate flow rate through extended front port channels while maintaining clearance from mould walls by utilizing lateral space
3Reliability
If front ports extend downwards to fill corners, then corner filling is improved, but flow stability and thermal profile control become difficult
Solution Approach 1:
Different front ports are designed with different characteristics suited to their specific functions. Front ports directing to corners may extend downwards or at angles, while others maintain horizontal orientation for flow stability. Each front port's geometry and orientation is locally optimized for its specific filling requirement, allowing corner filling while maintaining overall flow stability through differentiated design
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
The nozzle design achieves a more stable metal flow and reduced turbulence, resulting in lower defect concentrations and improved filling of complex-shaped metal beams with enhanced control over metal jets, thereby increasing the service life of moulds and reducing production costs.
Implementation Method 1
Flow of metal melt out of a metallurgic vessel is driven by gravity through a nozzle system (1, 111) located at the bottom of said vessel
Data Source
AI summary
A nozzle for casting steel contains an inlet portion, an elongated portion extending along a first longitudinal axis, an outlet portion and a pouring bore having a front port inlet. A planar cut of the nozzle outlet portion normal to the first longitudinal axis passing through the front port inlet contains the outline of the bore, the outline of the outer peripheral wall of the outlet portion of the nozzle, and a first transverse axis. In the planar cut, the bore centroid and wall centroid are distinct and separated by a distance, d≠0; and the segment extending along the first transverse axis, from the bore centroid, to the wall perimeter is longer than the segment extending from the wall centroid to the intersecting point between the first transverse axis and the wall perimeter.