Upper Nozzle Bore Curvature for Molten Steel Flow Stability
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Solution Overview
Problem
Existing upper nozzles fitted into discharge openings of ladles or tundishes face challenges with deposit formation due to rapid pressure changes in the molten steel flow, leading to potential clogging and increased operational costs, especially since gas injection-type nozzles are complex and costly, and previous solutions do not effectively address deposit formation throughout the casting process.
Innovation Solution
The upper nozzle features a bore surface configuration defined by specific curves, ensuring continuous differential values, which stabilizes the pressure distribution and minimizes energy loss, thereby creating a smooth molten steel flow that suppresses deposit formation. The bore surface is designed using formulas such as log(r(z))=(1/n)×log((H+L)/(H+z))+log(r(L)), with n ranging from 1.5 to 6, ensuring at least 80% of the surface follows this configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a reverse taper region is formed on the upper side of the upper nozzle, then the structure is simplified and manufacturing is easier, but rapid pressure change occurs in the straight region leading to deposit formation
Solution Approach 1:
The invention applies curvature by defining the bore surface configuration using a specific mathematical curve (log(r(z))=(1/n)×log((H+L)/(H+z))+log(r(L))) that ensures continuous differential values. This curved configuration eliminates the sharp transitions between reverse taper and straight regions, creating a smooth flow path that prevents rapid pressure changes and deposit formation while maintaining manufacturing feasibility.
2Object-affected harmful factors
If gas injection ports are added to prevent deposit formation, then deposit suppression is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts and eliminates the need for gas injection ports by addressing the root cause of deposit formation through bore surface configuration optimization. By designing the bore with continuous differential curvature, the patent achieves deposit suppression through flow stabilization alone, removing the complex gas injection system entirely.
Solution Approach 2:
The bore surface configuration serves itself to prevent deposit formation by creating a smooth flow path that avoids rapid pressure changes. The geometric design inherently stabilizes the molten steel flow, making external intervention through gas injection unnecessary.
3Object-affected harmful factors
If arc-shaped region is used instead of straight region, then rapid pressure change is suppressed, but arc-curved pressure change occurs and manufacturing complexity increases
Solution Approach 1:
The invention changes the geometric parameters of the bore surface by using a specific mathematical curve definition with adjustable parameter n (where 1.5 ≤ n ≤ 6.0). This parameter optimization allows tuning of the curvature to achieve continuous differential values that suppress rapid pressure change while controlling manufacturing complexity through a well-defined mathematical relationship.
4Ease of manufacture
If conventional bore configurations are used, then manufacturing is easier, but pressure distribution is unstable leading to energy loss and deposit formation
Solution Approach 1:
The invention applies continuous curvature through the mathematical curve definition that ensures continuous differential values throughout the bore surface. This smooth curved configuration eliminates abrupt geometric transitions, stabilizing pressure distribution and reducing energy loss in molten steel flow while remaining manufacturable through precise geometric control.
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 configuration results in a consistent pressure distribution along the bore surface, reducing energy loss and effectively preventing deposit formation, even during non-last stages of molten steel discharge, thus enhancing the operational efficiency and reducing the likelihood of clogging.
Implementation Method 1
stabilizes the pressure distribution and minimizes energy loss, thereby creating a smooth molten steel flow
Implementation Method 2
minimizes energy loss, thereby creating a smooth molten steel flow
Implementation Method 3
effectively preventing deposit formation, even during non-last stages of molten steel discharge
Data Source
AI summary
The present invention is directed to creating a less-energy loss or smooth (constant) molten steel flow with a focus on a configuration of a bore of an upper nozzle, so as to provide an upper nozzle formed with a bore having a configuration capable of to suppress deposit formation. For this purpose, in an upper nozzle 10 for allowing molten steel to flow therethrough, a radius of an upper end of a bore 11 is set to be equal to or greater than 1.5 times a radius of a lower end of the bore 11, and a bore surface 14 is formed in a vertical cross-sectional configuration represented by log(r(z))=(1/n)×log((H+L)/(H+z))+log(r(L))(n=1.5 to 6).