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Casting and Foundry Work
Published in Sherif D. El Wakil, Processes and Design for Manufacturing, 2019
The continuous casting process basically involves controlling the flow of a stream of molten metal that comes out from a water-cooled orifice in order to solidify and form a continuous strip (or rod). The new version of this process is usually referred to as rotary continuous casting because the water-cooled mold (orifice) is always oscillating and rotating at about 120 revolutions per minute during casting. Figure 3.15 illustrates the principles of rotary continuous casting. The steel is melted, refined, and degassed and its chemical composition controlled before it is transferred and poured into the caster (tundish). The molten metal then enters the rotating mold tangent to the edge through the bent tube. The centrifugal force then forces the steel against the mold wall, while lighter inclusions and impurities remain in the center of the vortex, where the operator removes them. Solidification of the metal flowing out of the mold continues at a precalculated rate. The resulting bar is then cut by a circular saw that is traveling downward at the same speed as the bar. The bar is tilted and loaded onto a conveyor to transfer it to the cooling bed and the rolling mill.
Energy Efficiency and Conservation Technologies
Published in Swapan Kumar Dutta, Jitendra Saxena, Binoy Krishna Choudhury, Energy Efficiency and Conservation in Metal Industries, 2023
Jitendra Saxena, Binoy Krishna Choudhury
Typical features of a HSM plant (Figure 3.10) are as follows: Capacity: 3.0 MTPA Phase I: 1.5 MTPAPhase II A: 0.9 MTPAPhase II B: 0.6 MTPATwin shell CONARC furnace capable of using different combinations of charge mix of hot metal, sponge iron and scrapAbility to roll as thin as 1.2 mm with 1,250 mm widthCapable of producing ultra-low-carbon steels/electrical steels through VOD/VCD/VD routeHR as a substitute for CR in certain applications due to superior surface quality and thinner gaugesRolling mills have HGC, AGC, CVC and roll bending in all six standsRoll shifting facility in all stands of +/− 100mm for better profile Brief description of the process: In HSM, HR coil is produced from the liquid metal. The main raw materials for this section are hot metal from a blast furnace, sponge iron from SIP and electrical power from MSEB. Basically, it is a continuous casting process. Continuous casting is the process whereby molten steel is solidified into a “semi-finished” billet, bloom or slab for subsequent rolling in the finishing mills.
Modelling of thermofluidic behaviour and mechanical deformation in thin slab continuous casting of steel: an overview
Published in Canadian Metallurgical Quarterly, 2021
Pedduri Jayakrishna, Saurav Chakraborty, Suvankar Ganguly, Prabal Talukdar
Continuous casting has been the most widely used process of producing steel products from molten steel in various basic shapes which undergo subsequent operations to reach final shapes. The aim of reducing the product cost, energy consumption, intermediate steps involved while producing hot rolled coils (HRC) from semi-finished castings and direct integration of near net shape casting with rolling mill motivate the steel industries to develop various types of thin slab casting and rolling technologies. Among them, the most notable technologies are Compact Strip Production (CSP) [9–13], In-line Strip Production (ISP) [14], Continuous Thin Slab Casting and Rolling (CONROLL), Quality Strip Production (QSP) [1], Flexible Thin Slab Casting (FTSC) [9,15] technologies, etc. In these technologies, the semi-finished products that are produced in thin slab casters (funnel or parallel type moulds) using liquid metal are heated up to rolling temperature in a reheating furnace before passing to the rolling mill and finally, the hot strips formed in the finishing or rolling mill are cooled and rolled to coils. The reasons for these technologies to become famous are due to continuous improvements in the design of mould and SEN, usage of high quality mould powders, application of advanced Electromagnetic brakes (EMBr) and Dynamic liquid core reduction (LCR), Water spray cooling and Hydraulic mould oscillations, etc.
Smith predictor-based multiple periodic disturbance compensation for long dead-time processes
Published in International Journal of Control, 2018
Fang Tan, Han-Xiong Li, Ping Shen
In the steel industry, the continuous casting is the most used process to solidify the molten steel. As shown in Figure 7, molten steel flows from the ladle, through a tundish and into the molud, and then is solidified by the water cooled mould walls. A solid shell is thus formed and continuously withdrawn out of the mould. Through rolls and under constant cooling, the steel is fully solidified. During the continuous casting process, periodic oscillations occur and affect the control of the mould level. They are caused by an additional flow of liquid steel toward and beyond the solid shell (Furtmueller & Gruenbacher, 2006). So, suppressing periodic disturbances is important for the casting quality. The casting system can be modelled as the following transfer function (Jabri et al., 2008):
Numerical prediction of solidified shell thicknesses obtained in continuous casting with different billet shapes
Published in Numerical Heat Transfer, Part A: Applications, 2020
Sanket Ashok Bhole, Manish Kumar, Somnath Roy, Sudhansu Sekhar Panda
Continuous casting is widely preferred over traditional metallurgical processes as it provides better yield, productivity, quality, cost efficiency and applicability. Simulations of such casting processes (i.e. Simulation of solidification of metals and alloys in different ambiences and boundary conditions involved in various manufacturing processes) have been increasingly used in modern foundries and metal casting industries [1–9]. The schematic of a typical continuous casting process is represented in Figure 1. At the beginning of the process, a dummy bar (starter bar) is placed horizontally at the end to restrain the liquid metal from spilling. Depending upon the applications, the mold shapes vary from simple rectangular to more complex round, elliptic or I-shaped mold [10].