Composition and structural characteristics of aluminum and aluminum alloy rod continuous casting and rolling production line

A, four-wheel continuous caster

The four-wheel continuous caster is imported from Italy Propez company technology, our company digests and absorbs the design and manufacture. Mainly composed of pouring fort, crystal wheel and transmission device, pinch wheel device, steel belt oiling device, approach bridge, tension wheel device, external cooling device, plug, ingot picker steel belt, etc., all parts are installed in the machine Body.

The molten aluminum flows from the holding furnace through the launder into the middle fort. The floating plug uses the principle of leverage to control the flow of the molten aluminum into the lower pouring fort (see Figure 1 and Figure 2). In the mold cavity formed by the crystal wheel and the closed steel belt. The entire pouring fort can be moved up and down by the motor, turbine reducer and screw pair. The cross section of the crystal wheel is H-shaped, which is controlled by AC motor frequency conversion (or DC motor) and driven by a gear box. The cooling device of the crystal wheel is controllable internal cooling, external cooling, internal cooling, and external cooling. It is sprayed to each zone through a cooling water nozzle with a pressure of about 0.5Mpa. The cooling water temperature is below 35℃, and the water volume can be passed through the shut-off valve. To adjust. As a result, the temperature of the cast aluminum liquid is gradually cooled from 700°C to 710°C and solidified into an aluminum ingot with a temperature of 480°C to 520°C.

The solidified ingot on the crystallizing wheel is ejected by the ingot ejector and sent out along the approach bridge. The pinch wheel device presses the steel belt tightly on the crystallizing wheel to prevent the aluminum liquid from leaking out. The guide wheel device is used to adjust and change the direction of the steel strip and the length of the mold cavity. It can be adjusted within a certain range. The tension and compression of the steel strip are adjusted by the cylinder, so that the tension of the steel strip can be maintained at a certain tension. In order to facilitate the demoulding of aluminum ingots, the continuous casting machine is also equipped with crystallizing wheels, steel strip oiling device and steel strip drying device. Since the whole process is continuous, and the three elements of casting temperature, casting speed, and cooling conditions are strictly controlled, large-length ingots can be obtained.

The crystal wheel is made of silver-copper alloy (Ag-T2) , and the structure of the crystal wheel has been improved in strength, which has a longer life than the original crystal wheel. The middle fort lining adopts a high-strength integral silicon carbide refractory lining, which is strong and durable and eliminates the secondary pollution of the aluminum liquid caused by refractory materials in the past. And at the junction of the launder and the middle fort, a duct is used for diversion. The aluminum liquid casting adopts 12-point horizontal casting, which can make the aluminum liquid enter the crystallization cavity smoothly, without turbulence and turbulence, and keep the launder and the middle fort. The oxide film on the surface of the inner molten aluminum is not destroyed, reducing the re-inhalation and oxidation of the molten aluminum, preventing the oxide film from entering the casting cavity to form new slag, thereby improving the quality of the ingot and aluminum rod.

B, continuous rolling mill

Aluminum alloy has higher hardness and strength than ordinary aluminum, and its rolling force during rolling is also greater than that of ordinary aluminum. Large rolling force is a significant feature of rolled aluminum alloy rods.

It is composed of 12 racks and is specially designed and manufactured for the production of aluminum and aluminum alloy rods.

There is an active feeding mechanism at the entrance of the rolling mill. The continuous rolling mill is composed of 2 sets of independent transmission two-roll special stands and 10 sets of Y-shaped three-roll stands driven by a main motor and a gear reducer. The nominal roll diameter is Ф255mm, and it is a horizontal machine. There are 1 pair each for the frame and vertical roller frame, 10 pairs of Y-frames have 5 pairs of upper transmission and 5 pairs of lower transmission, which are arranged alternately on the left and right. The second roller adopts the arc circle and one circle system pass, and the three roller adopts the arc triangle and one circle system pass. Two independent racks are driven by 55 and 45kw AC motors through a pin-vibration reducer, and 10 Y-shaped three-roller racks use 280kw DC motors to transmit power through the shaft coupling and the main shaft of the transmission gear box.

There are safety gear couplings at the connection between the transmission tooth box and the frame, and the safety pin is cut off when overloaded to protect the gears and shafts on the frame. Each pair of racks is equipped with entrance and exit guide guards at the front and rear. The entrance of the even-numbered rack adopts a sliding guide guard, and the entrance of the odd-numbered rack adopts a rolling guide guard, which is consistent with the triangular rolling piece coming out of the previous one, and has a proper gap. The guide and guard device installed at the exit of the frame adopts a Huff structure. Once a stacking accident occurs, the pipe will be flushed out to prevent the frame from being blocked. A stacking automatic parking device is installed between the frame and the frame.

The small arch of the side roller of each frame can be adjusted by shims, and the adjustment pieces with different thicknesses are in the form of Huff, so that the shims can be replaced without unscrewing all the four fixing bolts. The adjustment range is ±0.5mm.

The main box gear adopts high-precision gears with low noise and long life. The internal structure of the stand is made of aluminum alloy rolling mill high-strength components, and the roll material is H13 . The rolls, gears, and shafts are all upgraded with high strength, and the service life is long. Both the oil lubrication system and the emulsion lubrication system are dual systems, which can easily and quickly eliminate emergency accidents.

C, Aluminum alloy conic water-packed roller type oil-free lead loop forming device

The aluminum alloy conic water-packed roller type oil-free lead loop forming device is an upgraded product on the basis of the patented conic water-filled roller type oil-free lead loop forming device. The patented product is suitable for A2-A8 aluminum rods and aluminum alloy rods to form oil-free lead rods. The outstanding features have become the first choice for users of the new aluminum and aluminum alloy continuous casting and rolling production lines.

More than 50 original ordinary aluminum continuous casting and rolling production lines have been successfully transformed into a conic water-filled roller type oil-free lead ring, which has won the praise of users. We have mastered the oil-free lead rod throughout the entire process, the running track, swing form, and force change of each point in the conic water-filled roller lead rod. Targeted optimization and improvement, the advanced structure solves 5 major problems: 1. The lead rod does not need butter; 2. The broken rod is automatically brought out without blocking the rod; 3. The whole raceway is free of scratches; 4. The innovative structure makes aluminum The rod deformation force and the loop-forming release force are in the best state and the loop-forming is good (A2-A8); 5. Reduce the hard and soft problems of the aluminum rod outside the loop.

The final process of the primary aluminum all-gold rod continuous casting and rolling production line is to pass the rolled aluminum all-gold rod through the lead rod, quench it, actively traction, and wrap the rod into a circle into a frame. The main structure of the original lead rod is: small arc roller sharp rise + straight pipe and water bag combination + drying system + head roller arc + host traction + winding rod and frame + auxiliary pipeline cooling water system, which is generally active Traction method. The aluminum alloy conic water-packed roller type lead loop forming device adopts a passive type. After the rolling mill is out of the rod, the aluminum alloy rod or aluminum rod enters the conic water-filled roller type oil-free lead rod loop forming device through the bell mouth of the guide rod. The moving aluminum rod or aluminum rod drives the rollers in the lead pipe to rotate all the way to carry it forward. The main structure is: quadratic curve water bag roller combination system + water bag combination + drying system + new-style head roller arc assembly + round rod forming ring frame + emulsion and cooling water input and output dual-switching pipelines The system adopts non-active traction mode.

Aluminum alloy quadratic curve water-packed roller-type oil-free lead rod loop forming device, attached water pipe, return pipe, switching box, the design structure is both emulsion and cooling water input and output dual-switching type, in order to realize the common aluminum rod and Aluminum alloy rod produces dual functions. When producing ordinary aluminum rods, close the auxiliary pipeline cooling water system valve, open the emulsion system valve, and use the rolling mill emulsion main pipeline to branch into the upper water pipe, and the branch ring is evenly sprayed into the conic tube water bag device for segmentation Cooling and lubrication, the flow rate can be adjusted online. The above emulsion flows back into the main return pipe, flows into the emulsion groove through the split emulsion valve in the switching box, and can produce ordinary aluminum rods. When producing aluminum alloy rods, close the auxiliary pipeline emulsion system valve, open the cooling water system valve, close the input split emulsion valve, open the emulsion drain valve at the upper water pipe end, drain the remaining emulsion in the upper water pipe, and close the return switch The tank is connected to the emulsion diversion valve, and the cooling water and return valve are turned on to produce aluminum alloy rods.

The disadvantage of active traction, the active traction system needs to track the speed of the main engine and perform speed matching control. The line speed of the active traction wheel should be slightly faster than the line speed of the final rolling stand of the main machine, otherwise the meaning of active traction will be lost, but the line speed of the active traction wheel is not synchronized with the line speed of the final rolling stand of the main machine, so it is continuous in the aluminum The surface of the rod is slipped and gnawed. At the same time, the aluminum rod is subjected to the combined force of traction and self-gravity in the guide tube, causing the aluminum rod to continuously swing up and down to scrape the tube wall. Due to the low strength of the aluminum rod, the surface of the aluminum rod was scratched and scratched by the active traction wheel. Therefore, in all production lines with active traction system, even if many users adopt the method of adding butter rod, a large amount of needle-shaped aluminum chips can be seen under the active traction wheel.

The original intention of adopting the active traction method was mainly due to the fact that it is difficult to wind the aluminum alloy rod into a circle because of its high strength. The active traction force is adopted to make it pass through the swing head. In actual production, the pre-deformed spiral swing head is not easy to use in the production of ordinary aluminum rods. Most users have already thrown the pre-deformed spiral swing head. The club head is changed to ordinary aluminum swing head to produce aluminum alloy rods that are not extremely high in strength. Not only can the aluminum alloy rods be folded into a circle, but also the effect is very good. It can be seen that it is not necessary for the aluminum alloy production line to adopt an active traction method, and in actual production, the manufacturers use ordinary aluminum swing heads. Both the aluminum alloy production line and the ordinary aluminum production line should adopt the passive lead method as the best, which not only saves the cost of the active traction system and the matching control system, but also does not cause the surface of the aluminum rod to be scratched when producing ordinary aluminum rods.

Aluminum alloy conic water bag roller type oil-free lead loop forming device consists of: aluminum alloy conic curve water bag roller type lead rod integrated system, roller head swing system, random spare parts, water supply system, switch box, valve , Blowing system, inclined climbing ladder and four-pillar platform, special matching worm gear reducer for winding rod, motor Y112M-4 4kw 1440r/min B5, retractable double frame, mobile trolley and track, electronic control.

D , electrical control system

The electrical system is powered by a three-phase four-wire 380V, 50Hz, low-voltage network, and the total power of the equipment is about 795kw. Among them, the 280kw DC motor is controlled by Siemens DC speed regulating device, which has strong protection characteristics and fault diagnosis function. The casting machine motor, independent transmission frame motor and rod winding machine motor are AC motors, which are controlled by Siemens AC frequency conversion speed control unit. Intermediate relays and AC contactors below 32A use Siemens 3TB series, air switches below 25A use Siemens 3VU1340 series, and the rest are selected from well-known domestic manufacturers. The PLC uses Siemens S7-200 for programming, and the touch screen uses Eview 10.4-inch man-machine interface color touch screen digital control. Various operating parameters are centrally monitored and displayed. Process parameters can be set, modified, and displayed through the man-machine interface. The electric control cabinet should be placed in a dedicated power distribution room, and only the rolling mill operation table, casting machine operation table and pole winding machine operation table should be placed on the production site, and the junction box of the pump unit should be placed near the pump unit. The whole unit is easy to operate and convenient to maintain. In terms of casting speed, rolling speed and traction speed, the linkage matching program can be set electrically to ensure the synchronization of the production line and fine-tuning during operation, making the operation simple and convenient.

F . Purchaser’s own part

1. Melting furnace, holding furnace and launder.

2. The cooling water circulation system of the crystal wheel of the casting machine, the water supply system for the heat exchange water of the chiller of the unit (including the cooling water pump, the drain water pump, the cooling tower, the valve and the pipeline, etc.).

3. Provide connection wires and cables from the power main network to the equipment electric control cabinet, the electric control cabinet to the fuselage control point, and the electric control cabinet.

H. Capacity of assembly machine for aluminum rod continuous casting and rolling mill: