Vane Whirl Nozzle for Uniform Metal Casting Cooling
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Solution Overview
Problem
Existing pressurized air assisted spray nozzle assemblies in continuous metal casting systems face challenges in reliably generating a full cone preatomized liquid spray discharge with uniform particle distribution, as they often require small and expensive whirl imparting vanes that are prone to clogging.
Innovation Solution
The design incorporates a whirl directing vane with large, V-shaped passageways that facilitate uniform liquid particle distribution and mixing, preventing clogging, and allowing for precise and economical manufacturing, enabling the production of a full cone liquid spray pattern with enhanced coverage in continuous metal casting systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a whirl imparting vane is used to generate a full cone spray pattern, then the liquid particle distribution is improved, but the vane is small in size, difficult and expensive to manufacture, and subject to clogging
Solution Approach 1:
The liquid flow is divided into multiple streams by the vane's circumferentially spaced passages, with each passage directing a portion of the liquid tangentially to create the full cone spray pattern. This segmentation allows the liquid to be distributed uniformly while using larger, less susceptible passages to clogging
Solution Approach 2:
The vane features a central orifice and circumferential passages with different functions - the central orifice provides additional liquid flow while the circumferential passages create the swirling motion. Each region of the vane is optimized for its specific function, improving overall performance while maintaining manufacturability
2Manufacturing precision
If a whirl imparting vane is used to generate a full cone spray pattern, then the liquid particle distribution is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The vane is designed with segmented passages (central orifice and circumferential passages) that can be manufactured using standard machining operations. The segmentation allows for modular manufacturing and assembly, reducing overall complexity while achieving the desired spray pattern
Solution Approach 2:
The vane serves multiple functions simultaneously - it imparts whirl motion to the liquid, distributes liquid uniformly, and creates the full cone spray pattern. This multi-functionality reduces the need for additional components, simplifying the overall system while maintaining manufacturing feasibility
3Device complexity
If a flat spray pattern is used in continuous metal casting, then the spray nozzle alignment is simplified, but the coverage completeness for square billets is reduced
Solution Approach 1:
The spray pattern is changed from a flat (planar) configuration to a full cone (three-dimensional) configuration. This spherical/conical distribution of liquid particles provides complete coverage of the square billet surfaces, including top, bottom, and side surfaces, maximizing the cooling effectiveness
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 solution effectively directs a full cone spray pattern with uniform particle distribution, ensuring efficient and complete cooling of billets while maintaining a constant spray angle over a wide pressure range and reducing the risk of clogging, thus improving the cooling efficiency and manufacturing feasibility of the spray nozzle assembly.
Implementation Method 1
a liquid stream and a pressurized air stream are introduced tangentially to the chamber in opposite directions to be preatomized within the chamber
Implementation Method 2
The swirl inducing vanes are adapted for directing the preatomized liquid particles into a full cone spray pattern
Data Source
Figure 1~3
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Figure 9~10
AI summary
A full cone liquid spray nozzle is provided. The spray nozzle includes a nozzle body having a discharge orifice at a downstream end and an inlet at an upstream end for connection to a liquid supply. A liquid flow passageway extends through the nozzle body communicating between the inlet and the discharge orifice. A vane is disposed in the liquid flow passageway upstream of the discharge orifice. The vane has a plurality of V-shaped passageways therein. Each V-shaped passageway extends inward at an angle with respect to a longitudinal axis of the vane between an upstream face and downstream face of the vane. A whirl and mixing chamber defined by the liquid flow passageway is arranged between the vane and the discharge orifice.