CA2049926A1 - Process and apparatus for producing molded shapes - Google Patents
Process and apparatus for producing molded shapesInfo
- Publication number
- CA2049926A1 CA2049926A1 CA002049926A CA2049926A CA2049926A1 CA 2049926 A1 CA2049926 A1 CA 2049926A1 CA 002049926 A CA002049926 A CA 002049926A CA 2049926 A CA2049926 A CA 2049926A CA 2049926 A1 CA2049926 A1 CA 2049926A1
- Authority
- CA
- Canada
- Prior art keywords
- mold
- forming means
- discrete
- casting
- continuous casting
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D5/00—Machines or plants for pig or like casting
- B22D5/04—Machines or plants for pig or like casting with endless casting conveyors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
- B22D11/0605—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars formed by two belts, e.g. Hazelett-process
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/12—Accessories for subsequent treating or working cast stock in situ
- B22D11/126—Accessories for subsequent treating or working cast stock in situ for cutting
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Continuous Casting (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
- Nonwoven Fabrics (AREA)
Abstract
ABSTRACT
Continuous casting of discrete solid shapes (33) from a molten material (11) using modified continuous casting machines and processes are disclosed. In a conventional twin belt continuous caster, for example, forming means (27) such as dividers are employed on the upper belt (14) to define a mold cavity in the casting region of the machine. Different size and shape forming means (27) may be used to provide a variety of cast products.
Continuous casting of discrete solid shapes (33) from a molten material (11) using modified continuous casting machines and processes are disclosed. In a conventional twin belt continuous caster, for example, forming means (27) such as dividers are employed on the upper belt (14) to define a mold cavity in the casting region of the machine. Different size and shape forming means (27) may be used to provide a variety of cast products.
Description
9~6 The present invention relate to machines and processes for the casting of discrete solid shape~ from a flowable; moldable or molten materialO Specific:ally, the inventlon disclose~ continuously ca~ting disc~ete shapes using a static mold ca~ting ~achine or, preferably, a moving mold casting machina whera, ~or example, the shapes aro form~d between spaced port:ions o~ a palr o~ endless ~lexible casting belt~ wh~ch ara moved along with opposit~ sur~aces o~ th~ matal be~ng cast~
Although the principles of the invention can be used to cast any ~lowabls, moldabl~ or molten material such as plastlcs~ the invention will be described in terms of continuously casting molten metal }5 into discrete and variabla shapes, such as ingot~, anodes, wirebars or ~oundry castings.
Discrete metallic shapes are typically cast in individual molds using a discontinuou~ stream of molten metal. A plurality of mold cavities are supplied sequentially and the flow of metal in the desired quantity to each of the molds is controlled manually by an operator or in an automated manner. Continuous casting is employed, in a variety of forms, in the nonferrous and ferrous metals industry and elsewhere, to decrease production cost and increase product quality.
Two basic systems known as the static and moving mold methods are used in continuous casting o~E shapes such as billets or continuous strips. In the static mold casting machine, the walls of the mold are stationary, while the cast products move against and solidi~y within tham. Moving mold casting machines emplvy a belt, chain, drum, wheel, or other surface which moves at approximately the same speed as the solidifying metal.
The continuous casting of metal on moving mold casting machines having at least one movable belt and a corresponding fixed or movable surface which together form a mold of two opposed surfaces in which the cast material solidifies is described in detail in the ~ollowing U~S. patents which are incorporated herein by re~erence: 2,631,343; 2,904,860; 3,036,348; 3,123,873;
3,123,8~4; 3,167,830; 3,533,4~3, 3,864,973; 3,878,883;
3,921,697; 3,9~7,270; 3,937,~74: 3,94~,8~5; 3,955,~15;
~,002,197; and 4,854,371.
For a twin belt caster where two movabl~ belts form the mold, in operation, a continuou~ strea3n of molten metal is supplied at the inlet of the machine to a cavity ~ormed by a pair of movable flexible casting belts, positioned generally above the other, and side dam blocks, and emerges at the other end of the cavity (outlet of the machine) as a solidified strip or bar of metal. The strip or bar is subsequently fed to other apparatus for mechanical working, or cutting and~or welding, which changes its cross sectional dimensions.
For example, twin belt casters o~ the type desc:ribed are used to convert molten copper to a roughly rectangular bar shape which is then continuously fed to a rolling mill ha~Ting a series of rolling stages for converting the rectangular bar to a round rod. Typically, the rod eventually is drawn to wire of various gauges.
In a previous attempt in the art to produce shaped articles continuously, a twin belt caster was modified by making the dam blocks smaller at certain inter-rals to provide a cast material having the shap~ of an anode, i.e., a flat rectangular shape having support arms. After casting, however, the casting had to be cut ~o form discrete anode shapes.
Another continuous casting moving mold method employs ~ casting wheel ha~ing a peripheral groove therearound. A portion of the peripheral groove is closed by an endless belt to form a mold into which molten metal is poured to be solidified into cast metal and discharged therefrom. Such designs may be seen in U.S. Patent Nos 3,279,000 and 3,46~,620, which patents are hereby incorporated by reference.
Continuous casting using a static mold may be found in U.S. Patent Nos. 2,938,251; 2,946,100;
3,066,364; 3,0~9,209; 3,098,269; and 3,115,686, which patents are here~y incorporated by reference.
Basically, molten metal i~ continuously ~ed into the mold, freezes and the frozen product continuously removed from the mold. Generally, the mold is in a vertica} position with the molten metal poured into the top of the mold.
While the casting machines described hereinabove are very successful and employed extensively throuqhout industry, the need still exists for these typa continuous casting machines to produce discrete shapes. It is an object of the invention to provide apparatus and methods for the cont;nuous casting of such discreta shapes.
SUMMARY OF THE INVENTION
The present invention is directed to an improvement in continuous casting machines and comprises apparatus and method for using a continuous casting machine to cast discrete shapes such as wire bars, ingots, billets, cakes, strips and foundry shapes from a stream of molten material. A~though the invention can be employed in connection with various types of continuous casting machines, the invention for convenience wi~l be described in detail for casting lead 2~
pigs using a twin belt caster wherein a pair o~ moving belts form a moving mold for molten metal.
The apparatus and method of the inv~ntion can be employed with any flowable, moldable or molten material such as plastlcs, ferrous or non~errou5 metals including but not limited to steel, iron, copper, lead, bismuth and aluminum. The invention is particularly useful for the continuous casting of brittle or frangible materials which cannot normally be rolled, roll-formPd, drawn or drilled in the solid state.
The method o~ the inventio~ comprises the steps of supplying a continuous stream of molten material to a mold, static or movinq~ forming the continuous stream of molten material into discrete) segments of predetermined volume and shape ~ olidifying said molten material and separating said segments into discrete shapes, said forming step taking pl~ce prior to any significant solidification of the molten metal. Tha ~orming step may be accomplished by using for~ng means such as inserts, dividers, spacers, and the like as will be described further hereinbelow.
The apparatus of the invention comprises a continuou~ casting machine having first means for def~ning a mold, said first means including a moving or static surface depending on the mold employed, second means for supplying a continuous stream of molten material to the mold, one or more forming members which form discrete chambers in the mold and form the molten material in the mold into a cast material in the form of discrete segments, solidifying means and separating means to separate the discrete segments into discrete shapes from the cast material. For a twin-belt caster the moving surface is planar whereas for a wheel ~aster the movin~ surface is curved. In a static mold, the mold is substantially stationa~y relative to the molten material and solidified material moving through the mold. Static molds frequently employ reriprocating or other vibrating motions while casting.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a schematic illustration of a twin-belt casting machine showing the improved forming means for forming discre~e shapes.
Fig. 2 is a side sectional view taken along a plane perpendicular to the input rolls and including the tundish, dam wall and molten metal.
Fig. 3 is a top view of the lower casting belt showing an ingot shape formed using a particular forming means.
Fig. 4 is a side view of the lower casting belt showing an ingot shape ~ormed using a particular forming means.
~ETAILEp DESCRIPTION OF 5'HE I~V~NTION
An illus~rative example cf a contlnuous ~etal castinq machine equipped with an emb~dimen~ of the present invention ls shown in Fig. 1. In this casting machine 10 molten metal 11 is supplied from a pouring box or ladle (not shown~ into a tundish 12. From the tundish 12, the molten ~etal 11 is ~ed into an input rsgion 13 formed between spaced parallel surfaces of upper and lower endless flexible castin~ belts 14 and lS, respectively. The cavity formed between the belts 14 and 15 and dam blocks 16 may be defined as the casting region 17 wherein the molten metal is cast into a desired shape and solidified. The casting belts are preferably fabricated from steel, or other alloys, which provide toughness and resistance to abrasion and physical damage as well as resistance to the temperature shocks and heat differential stresses undergone during casting.
The casting belts 14 and 15 are supported on and driven by an upper and lower carriage generally indicated at 18 and 19, respectively. Both carriages are mounted on a machine ~rame (not shown). Each carriage includes two main rolls which support, drive -- ,i and steer the casting belts. These rolls include upper and lower input rolls, 20 and 21, and upper and lower output rolls, 22 and 23, respectively.
A 1exible, endless side metal retaining dam 16 is disposed on each side of the casting belts to define the side edges o~ the casting region for confining the molten metal. The sicle dams 16 are quided at the input end of the casting apparatus 10 by crescent shaped member~ ~4 which are mounted on the lower carriage 19.
During the casting operation, the two casting belts 14 and 15 are driven at about the same linear speed by a driving mechanism and the upper and lower carriages are preferably downwardly inclined in the downstream direction, so that the casting r~gion 17 between the casting belts is inclined. ~his do~lward inclination facilitates flow of moltan me~l into tha casting region.
~fter the castings have solidified and leave the appaxatus as indicated at 25, secondary coo}er means 26 may be employed to completely solidi~y and/or cool the casting. The use of this technique i5 called "secondary cooling" and is used to generate hi~her casting speeds. The use of ~econdary cooling also ~acilitates removal of the forming means 27 from the cast metal by a thermal shock mechanism caused by different coefficients of expansion between the forming means and the cast metal. Greater differences between the coefficients will have a greater thermal shock and separation effect. The primary cooling means (not shown) is generally accomplished by the use of a high velocity moving liquid coolant travelling along the opposite sides of the belts 14 and 15 which form the mold.
The improved apparatus and method of the invention utilizes for u~gL~ z~ ehe castinq belts to provide a discrete shape in the mold and casting region 17 o the apparatus. The forming means 27 are preferably attached to the upper casting belt 14 and may vary in shape and spacing to define the desired mold shape in the casting region 17 o~ the apparatus.
Exemplary forming means designs are described hereinbelow.
In a preferred embodiment of the invention, an additional carrîage 28 and belt 29 are utilized to allow the forming means 27 to be separated from belt 14, collected in timing device 30 and positioned on belt 14 based on a predetermined desired spacing. By the use of this separator system, the weight ~and size) of the discrete shapes cast during the casting operation may be varied by adjusting the timing device 30. Carriage 28 may employ two rolls 31 and 32 as indicated.
The discrete shapes 33 are ~ed out oP the casting apparatus and transported to a desired location.
The caster 10 and the tundish 12 are preferably of the "open pool" type with the tundlsh outlet specially modified to permit the ~orming means 27 to enter the casting area 17. The pool of molten metal at the caster inlet 13 preferably fills the inlet 50 that the forming means 27 contacts the molten metal 11 at the inlet 13.
The tundish tip is preferably made of graphite or other soft, ablating material which will also help the casting and lubrication of the lower belt 15. A
drawing of the proposed arrangement is shown in Fig. 2.
Since the metal, the belt, and the forming means all meet at approximately the same point, any gas or vapor behind the forming means 27 can escape into the open atmosphere and not cause a bubble to form behind the forming means in the metal casting. The da~ blocXs 16 preferably have a very slight taper on the internal surface ~larger at the bottom) to prevent the forming means from turning or otherwise moving inside the mold.
As the metal passes through the caster, - 8 -~-operation will be identical to a standard caster.
However, the casting rate will generally be accelerated or inhibited ~y the use of the ~orming means 27 which ac~ a~ heat sinks or insulator~ depending on th~
S material used for the ~orming mean~.
In a preferred emhodiment, the forming means 27 are removably attached, e.g., mag~etically, to belts 14 and 29. In operation, the forming means will be spaced on belt 14 and, as the belt rPvolves, the desired casting shape will be formed. After solidification, the discrete casting will be separated from the continuous cast strip (containing the forming means 27) with the forming means becoming magnetically attached and transferred to belt 29. The forming means ~7 wil:l then be transferred to the timing davice 30 where they will be al~gned and released again to belt 14 at the d~sired spacinq.
A device ~or separating the discrete castinys from the strip of castings made in tha caster ~ay be conveniently employed at point 34. For example, a bending movement may be applied to the casting wlth the forming means 27 taken off on belt 29 and transferred to the casting belt 14 as described hereinabove.
The designs for the forming means 27 can be quite variable. As shown in Fig. 3, a U-shape forming means 27 produces an ingot shape 33. Likewise, Fig. 4 shows an inverted T-shape forming means 27 which also produces an ingot shape 33. If required, boles, Yoids, indentations, brand names or other marks can be put into the casting with suitable forming means.
The forming means 27 may be made from a variety of materials. For magnetic dividers, the stronger the magnetic force of the forming means, the less internal taper or alignment will be needed to lock the forming means in the mold space. In some applications, it may even be desirable to make the forming means partly or wholly out o~ foundry sand, or ~t~
g refractory or metal beads as a substitut2 for drilling or casting complex holes and shapes in a casting or as a divider.
Removal of the ~or~ing mean~ 27 from the belt 14 and/or the casting may be facilit,ated by using forming means which are consumable ~such as wood) or disposable. Another design is to employ a thin, flexible walled forming means containiny a substance such as wat~r which expands when contacted with the lo molten metal (because of the generation o~ vapor or steam in the formin~ means) and which contracts upon cooling. Thus, as the forming means contact the molten metal 11 the forming means ~xpands and the casting is formed with the expanded for~ing means. After solidification and cooling, the ~orming means contracts facilitating its removal. A thin gauge ~talnless steel forming means may suitably be employed to cast lead pigs.
In an apparatus employing a casting wheel, fo~ming means 27 may be placed on the wheel or belt to define the discrete shape desired in the mold being formed by t~e peripheral groove in the casting wheel and the endless belt as discussed hereinabov~. For continuous casting using a static mold, the forming means 27 may be inserted into the mold cavity at clesired intervals to provide a separation between the molten metal (a division into discrete shapes~. Refractory beads may suitably be employed whereby the beads are fed into the mold cavity forming a separation between the molten metal being cast. The cast metal may then be easily separated into discrete shapes after solidification.
Although the principles of the invention can be used to cast any ~lowabls, moldabl~ or molten material such as plastlcs~ the invention will be described in terms of continuously casting molten metal }5 into discrete and variabla shapes, such as ingot~, anodes, wirebars or ~oundry castings.
Discrete metallic shapes are typically cast in individual molds using a discontinuou~ stream of molten metal. A plurality of mold cavities are supplied sequentially and the flow of metal in the desired quantity to each of the molds is controlled manually by an operator or in an automated manner. Continuous casting is employed, in a variety of forms, in the nonferrous and ferrous metals industry and elsewhere, to decrease production cost and increase product quality.
Two basic systems known as the static and moving mold methods are used in continuous casting o~E shapes such as billets or continuous strips. In the static mold casting machine, the walls of the mold are stationary, while the cast products move against and solidi~y within tham. Moving mold casting machines emplvy a belt, chain, drum, wheel, or other surface which moves at approximately the same speed as the solidifying metal.
The continuous casting of metal on moving mold casting machines having at least one movable belt and a corresponding fixed or movable surface which together form a mold of two opposed surfaces in which the cast material solidifies is described in detail in the ~ollowing U~S. patents which are incorporated herein by re~erence: 2,631,343; 2,904,860; 3,036,348; 3,123,873;
3,123,8~4; 3,167,830; 3,533,4~3, 3,864,973; 3,878,883;
3,921,697; 3,9~7,270; 3,937,~74: 3,94~,8~5; 3,955,~15;
~,002,197; and 4,854,371.
For a twin belt caster where two movabl~ belts form the mold, in operation, a continuou~ strea3n of molten metal is supplied at the inlet of the machine to a cavity ~ormed by a pair of movable flexible casting belts, positioned generally above the other, and side dam blocks, and emerges at the other end of the cavity (outlet of the machine) as a solidified strip or bar of metal. The strip or bar is subsequently fed to other apparatus for mechanical working, or cutting and~or welding, which changes its cross sectional dimensions.
For example, twin belt casters o~ the type desc:ribed are used to convert molten copper to a roughly rectangular bar shape which is then continuously fed to a rolling mill ha~Ting a series of rolling stages for converting the rectangular bar to a round rod. Typically, the rod eventually is drawn to wire of various gauges.
In a previous attempt in the art to produce shaped articles continuously, a twin belt caster was modified by making the dam blocks smaller at certain inter-rals to provide a cast material having the shap~ of an anode, i.e., a flat rectangular shape having support arms. After casting, however, the casting had to be cut ~o form discrete anode shapes.
Another continuous casting moving mold method employs ~ casting wheel ha~ing a peripheral groove therearound. A portion of the peripheral groove is closed by an endless belt to form a mold into which molten metal is poured to be solidified into cast metal and discharged therefrom. Such designs may be seen in U.S. Patent Nos 3,279,000 and 3,46~,620, which patents are hereby incorporated by reference.
Continuous casting using a static mold may be found in U.S. Patent Nos. 2,938,251; 2,946,100;
3,066,364; 3,0~9,209; 3,098,269; and 3,115,686, which patents are here~y incorporated by reference.
Basically, molten metal i~ continuously ~ed into the mold, freezes and the frozen product continuously removed from the mold. Generally, the mold is in a vertica} position with the molten metal poured into the top of the mold.
While the casting machines described hereinabove are very successful and employed extensively throuqhout industry, the need still exists for these typa continuous casting machines to produce discrete shapes. It is an object of the invention to provide apparatus and methods for the cont;nuous casting of such discreta shapes.
SUMMARY OF THE INVENTION
The present invention is directed to an improvement in continuous casting machines and comprises apparatus and method for using a continuous casting machine to cast discrete shapes such as wire bars, ingots, billets, cakes, strips and foundry shapes from a stream of molten material. A~though the invention can be employed in connection with various types of continuous casting machines, the invention for convenience wi~l be described in detail for casting lead 2~
pigs using a twin belt caster wherein a pair o~ moving belts form a moving mold for molten metal.
The apparatus and method of the inv~ntion can be employed with any flowable, moldable or molten material such as plastlcs, ferrous or non~errou5 metals including but not limited to steel, iron, copper, lead, bismuth and aluminum. The invention is particularly useful for the continuous casting of brittle or frangible materials which cannot normally be rolled, roll-formPd, drawn or drilled in the solid state.
The method o~ the inventio~ comprises the steps of supplying a continuous stream of molten material to a mold, static or movinq~ forming the continuous stream of molten material into discrete) segments of predetermined volume and shape ~ olidifying said molten material and separating said segments into discrete shapes, said forming step taking pl~ce prior to any significant solidification of the molten metal. Tha ~orming step may be accomplished by using for~ng means such as inserts, dividers, spacers, and the like as will be described further hereinbelow.
The apparatus of the invention comprises a continuou~ casting machine having first means for def~ning a mold, said first means including a moving or static surface depending on the mold employed, second means for supplying a continuous stream of molten material to the mold, one or more forming members which form discrete chambers in the mold and form the molten material in the mold into a cast material in the form of discrete segments, solidifying means and separating means to separate the discrete segments into discrete shapes from the cast material. For a twin-belt caster the moving surface is planar whereas for a wheel ~aster the movin~ surface is curved. In a static mold, the mold is substantially stationa~y relative to the molten material and solidified material moving through the mold. Static molds frequently employ reriprocating or other vibrating motions while casting.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a schematic illustration of a twin-belt casting machine showing the improved forming means for forming discre~e shapes.
Fig. 2 is a side sectional view taken along a plane perpendicular to the input rolls and including the tundish, dam wall and molten metal.
Fig. 3 is a top view of the lower casting belt showing an ingot shape formed using a particular forming means.
Fig. 4 is a side view of the lower casting belt showing an ingot shape ~ormed using a particular forming means.
~ETAILEp DESCRIPTION OF 5'HE I~V~NTION
An illus~rative example cf a contlnuous ~etal castinq machine equipped with an emb~dimen~ of the present invention ls shown in Fig. 1. In this casting machine 10 molten metal 11 is supplied from a pouring box or ladle (not shown~ into a tundish 12. From the tundish 12, the molten ~etal 11 is ~ed into an input rsgion 13 formed between spaced parallel surfaces of upper and lower endless flexible castin~ belts 14 and lS, respectively. The cavity formed between the belts 14 and 15 and dam blocks 16 may be defined as the casting region 17 wherein the molten metal is cast into a desired shape and solidified. The casting belts are preferably fabricated from steel, or other alloys, which provide toughness and resistance to abrasion and physical damage as well as resistance to the temperature shocks and heat differential stresses undergone during casting.
The casting belts 14 and 15 are supported on and driven by an upper and lower carriage generally indicated at 18 and 19, respectively. Both carriages are mounted on a machine ~rame (not shown). Each carriage includes two main rolls which support, drive -- ,i and steer the casting belts. These rolls include upper and lower input rolls, 20 and 21, and upper and lower output rolls, 22 and 23, respectively.
A 1exible, endless side metal retaining dam 16 is disposed on each side of the casting belts to define the side edges o~ the casting region for confining the molten metal. The sicle dams 16 are quided at the input end of the casting apparatus 10 by crescent shaped member~ ~4 which are mounted on the lower carriage 19.
During the casting operation, the two casting belts 14 and 15 are driven at about the same linear speed by a driving mechanism and the upper and lower carriages are preferably downwardly inclined in the downstream direction, so that the casting r~gion 17 between the casting belts is inclined. ~his do~lward inclination facilitates flow of moltan me~l into tha casting region.
~fter the castings have solidified and leave the appaxatus as indicated at 25, secondary coo}er means 26 may be employed to completely solidi~y and/or cool the casting. The use of this technique i5 called "secondary cooling" and is used to generate hi~her casting speeds. The use of ~econdary cooling also ~acilitates removal of the forming means 27 from the cast metal by a thermal shock mechanism caused by different coefficients of expansion between the forming means and the cast metal. Greater differences between the coefficients will have a greater thermal shock and separation effect. The primary cooling means (not shown) is generally accomplished by the use of a high velocity moving liquid coolant travelling along the opposite sides of the belts 14 and 15 which form the mold.
The improved apparatus and method of the invention utilizes for u~gL~ z~ ehe castinq belts to provide a discrete shape in the mold and casting region 17 o the apparatus. The forming means 27 are preferably attached to the upper casting belt 14 and may vary in shape and spacing to define the desired mold shape in the casting region 17 o~ the apparatus.
Exemplary forming means designs are described hereinbelow.
In a preferred embodiment of the invention, an additional carrîage 28 and belt 29 are utilized to allow the forming means 27 to be separated from belt 14, collected in timing device 30 and positioned on belt 14 based on a predetermined desired spacing. By the use of this separator system, the weight ~and size) of the discrete shapes cast during the casting operation may be varied by adjusting the timing device 30. Carriage 28 may employ two rolls 31 and 32 as indicated.
The discrete shapes 33 are ~ed out oP the casting apparatus and transported to a desired location.
The caster 10 and the tundish 12 are preferably of the "open pool" type with the tundlsh outlet specially modified to permit the ~orming means 27 to enter the casting area 17. The pool of molten metal at the caster inlet 13 preferably fills the inlet 50 that the forming means 27 contacts the molten metal 11 at the inlet 13.
The tundish tip is preferably made of graphite or other soft, ablating material which will also help the casting and lubrication of the lower belt 15. A
drawing of the proposed arrangement is shown in Fig. 2.
Since the metal, the belt, and the forming means all meet at approximately the same point, any gas or vapor behind the forming means 27 can escape into the open atmosphere and not cause a bubble to form behind the forming means in the metal casting. The da~ blocXs 16 preferably have a very slight taper on the internal surface ~larger at the bottom) to prevent the forming means from turning or otherwise moving inside the mold.
As the metal passes through the caster, - 8 -~-operation will be identical to a standard caster.
However, the casting rate will generally be accelerated or inhibited ~y the use of the ~orming means 27 which ac~ a~ heat sinks or insulator~ depending on th~
S material used for the ~orming mean~.
In a preferred emhodiment, the forming means 27 are removably attached, e.g., mag~etically, to belts 14 and 29. In operation, the forming means will be spaced on belt 14 and, as the belt rPvolves, the desired casting shape will be formed. After solidification, the discrete casting will be separated from the continuous cast strip (containing the forming means 27) with the forming means becoming magnetically attached and transferred to belt 29. The forming means ~7 wil:l then be transferred to the timing davice 30 where they will be al~gned and released again to belt 14 at the d~sired spacinq.
A device ~or separating the discrete castinys from the strip of castings made in tha caster ~ay be conveniently employed at point 34. For example, a bending movement may be applied to the casting wlth the forming means 27 taken off on belt 29 and transferred to the casting belt 14 as described hereinabove.
The designs for the forming means 27 can be quite variable. As shown in Fig. 3, a U-shape forming means 27 produces an ingot shape 33. Likewise, Fig. 4 shows an inverted T-shape forming means 27 which also produces an ingot shape 33. If required, boles, Yoids, indentations, brand names or other marks can be put into the casting with suitable forming means.
The forming means 27 may be made from a variety of materials. For magnetic dividers, the stronger the magnetic force of the forming means, the less internal taper or alignment will be needed to lock the forming means in the mold space. In some applications, it may even be desirable to make the forming means partly or wholly out o~ foundry sand, or ~t~
g refractory or metal beads as a substitut2 for drilling or casting complex holes and shapes in a casting or as a divider.
Removal of the ~or~ing mean~ 27 from the belt 14 and/or the casting may be facilit,ated by using forming means which are consumable ~such as wood) or disposable. Another design is to employ a thin, flexible walled forming means containiny a substance such as wat~r which expands when contacted with the lo molten metal (because of the generation o~ vapor or steam in the formin~ means) and which contracts upon cooling. Thus, as the forming means contact the molten metal 11 the forming means ~xpands and the casting is formed with the expanded for~ing means. After solidification and cooling, the ~orming means contracts facilitating its removal. A thin gauge ~talnless steel forming means may suitably be employed to cast lead pigs.
In an apparatus employing a casting wheel, fo~ming means 27 may be placed on the wheel or belt to define the discrete shape desired in the mold being formed by t~e peripheral groove in the casting wheel and the endless belt as discussed hereinabov~. For continuous casting using a static mold, the forming means 27 may be inserted into the mold cavity at clesired intervals to provide a separation between the molten metal (a division into discrete shapes~. Refractory beads may suitably be employed whereby the beads are fed into the mold cavity forming a separation between the molten metal being cast. The cast metal may then be easily separated into discrete shapes after solidification.
Claims (11)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A method for producing discrete molded shapes comprising supplying a continuous stream of molten material to a mold, inserting forming means into said mold at desired intervals so as to divide the molten metal into discrete segments, retaining said forming means in said molten material during its transition to a solid state so as to form substantially discrete molded shapes of said material, substantially solidifying said molten material, and removing the solidified material in the form of said discrete shapes.
2. A method according to claim 1, wherein the mold is a moving mold.
3. A method according to claim 2, wherein the moving mold is formed using a twin belt casting apparatus.
4. A continuous casting apparatus for forming discrete molded shapes (33) comprising a mold having moving or static surface, means (12) for supplying a continuous stream of molten material to the mold, one or more forming means (27) which form substantially discrete chambers in the mold and form the molten material in the mold into a cast material in the form of substantially discrete segments, said apparatus permitting cooling of said segments to the solid state, and separating means (34) to separate the discrete solid segments as discrete molded shapes (33) from the cast material.
5. A continuous casting apparatus according to claim 4, wherein the mold comprises a pair of upper and lower opposed substantially planar surfaces (14, 15) at least one which is movable and which together form the mold.
6. A continuous casting apparatus according to claim 41 wherein the forming means (27) are positioned at a desired spacing on the movable planar surface (14).
7. A continuous casting apparatus according to claim 6, comprising two movable planar surfaces (14, 15) with the forming means (27) positioned on the upper planar surface (14).
8. A continuous casting apparatus according to claim , wherein the two movable planar surfaces (14, 15) are belts.
9. A continuous casting apparatus according to any one of claims 6-8, wherein said forming means (27) are removably attached to said movable planar surface (14).
10. A continuous casting apparatus according to claim 9, which includes means (28, 29, 31, 32) for removing said forming means (27) from said planar surface (14), storing said forming means (27) and repositioning said forming means (27) on said movable planar surface (14).
11. A continuous casting apparatus according to claim 4, wherein the apparatus is a wheel caster, wherein the casting wheel has a peripheral groove therearound and a portion of the peripheral groove is closed by an endless belt to form a mold into which molten metal is poured and solidified into a cast material, forming means on the wheel ox belt to define discrete segments in the mold and separating means to separate the discrete segments into discrete shapes from the cast material.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US48645290A | 1990-02-28 | 1990-02-28 | |
| US07/486,452 | 1990-02-28 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2049926A1 true CA2049926A1 (en) | 1991-08-29 |
Family
ID=23931941
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002049926A Abandoned CA2049926A1 (en) | 1990-02-28 | 1990-12-28 | Process and apparatus for producing molded shapes |
Country Status (15)
| Country | Link |
|---|---|
| EP (1) | EP0470220B1 (en) |
| JP (1) | JPH04507065A (en) |
| KR (1) | KR100192692B1 (en) |
| CN (1) | CN1036254C (en) |
| AU (1) | AU639987B2 (en) |
| BG (1) | BG61184B1 (en) |
| BR (1) | BR9007316A (en) |
| CA (1) | CA2049926A1 (en) |
| DE (1) | DE69023135T2 (en) |
| ES (1) | ES2080298T3 (en) |
| FI (1) | FI96188C (en) |
| MY (1) | MY110424A (en) |
| PE (1) | PE17291A1 (en) |
| RU (1) | RU2081724C1 (en) |
| WO (1) | WO1991012910A1 (en) |
Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5339886A (en) * | 1993-01-11 | 1994-08-23 | Reynolds Metals Company | Method and apparatus for trimming edge scrap from continuously cast metal strip |
| DE19956479C2 (en) * | 1999-11-24 | 2001-11-22 | Hengst Walter Gmbh & Co Kg | Method and device for producing light metal pellets |
| CN1527751A (en) * | 2001-02-09 | 2004-09-08 | SMS�����ɷݹ�˾ | Method and device for casting and solidifying liquid metal and fragmenting said metal |
| FR2885544B1 (en) * | 2005-05-13 | 2009-01-16 | Fai Production Soc Par Actions | PROCESS AND PLANT FOR TRANSFORMING A LIQUID-LIKE METAL TO A SOLID AND FRAGMENTED METAL |
| US7156147B1 (en) * | 2005-10-19 | 2007-01-02 | Hazelett Strip Casting Corporation | Apparatus for steering casting belts of continuous metal-casting machines equipped with non-rotating, levitating, semi-cylindrical belt support apparatus |
| KR102538557B1 (en) | 2019-01-28 | 2023-06-01 | 노벨리스 인크. | Short belt side dam for twin belt casting machine |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US1690887A (en) * | 1926-06-05 | 1928-11-06 | Jasper N Davis | Process and machine for the manufacture of storage-battery plates |
| DE840753C (en) * | 1944-10-01 | 1952-06-09 | Wieland Werke Ag | Process and device for the production of composite metal blocks in the continuous casting process |
| US3502136A (en) * | 1967-07-17 | 1970-03-24 | Reliance Steel Products Co | Apparatus for the casting of gratings and other structures with parallel members and transverse connections |
| DE2531357C3 (en) * | 1975-07-14 | 1978-09-21 | Hans Dipl.-Ing. 4330 Muelheim Horst | Method and device for continuous casting of metals |
| BR7802482A (en) * | 1977-04-20 | 1979-04-03 | Bicc Ltd | PROCESS AND APPLIANCE FOR CONTINUOUS FOUNDATION OF UNINFINED ELECTRODES |
| LU79390A1 (en) * | 1978-04-06 | 1979-11-07 | Metallurgie Hoboken | CONTINUOUS CASTING PROCESS OF A METAL AND APPARATUS FOR ITS IMPLEMENTATION |
| US4285386A (en) * | 1979-03-16 | 1981-08-25 | Allied Chemical Corporation | Continuous casting method and apparatus for making defined shapes of thin sheet |
-
1990
- 1990-12-28 RU SU905001849A patent/RU2081724C1/en active
- 1990-12-28 KR KR1019910701190A patent/KR100192692B1/en not_active IP Right Cessation
- 1990-12-28 ES ES91904112T patent/ES2080298T3/en not_active Expired - Lifetime
- 1990-12-28 BR BR909007316A patent/BR9007316A/en not_active IP Right Cessation
- 1990-12-28 EP EP91904112A patent/EP0470220B1/en not_active Expired - Lifetime
- 1990-12-28 DE DE69023135T patent/DE69023135T2/en not_active Expired - Fee Related
- 1990-12-28 WO PCT/US1990/007691 patent/WO1991012910A1/en active IP Right Grant
- 1990-12-28 AU AU72437/91A patent/AU639987B2/en not_active Ceased
- 1990-12-28 JP JP91504346A patent/JPH04507065A/en active Pending
- 1990-12-28 CA CA002049926A patent/CA2049926A1/en not_active Abandoned
-
1991
- 1991-01-04 MY MYPI91000009A patent/MY110424A/en unknown
- 1991-01-09 PE PE1991180108A patent/PE17291A1/en not_active Application Discontinuation
- 1991-01-22 CN CN91100393A patent/CN1036254C/en not_active Expired - Fee Related
- 1991-09-23 FI FI914452A patent/FI96188C/en active
- 1991-09-23 BG BG95154A patent/BG61184B1/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| EP0470220B1 (en) | 1995-10-18 |
| EP0470220A1 (en) | 1992-02-12 |
| FI914452A0 (en) | 1991-09-23 |
| DE69023135D1 (en) | 1995-11-23 |
| CN1054385A (en) | 1991-09-11 |
| AU639987B2 (en) | 1993-08-12 |
| JPH04507065A (en) | 1992-12-10 |
| KR100192692B1 (en) | 1999-06-15 |
| BR9007316A (en) | 1992-04-28 |
| AU7243791A (en) | 1991-09-18 |
| EP0470220A4 (en) | 1992-11-25 |
| KR920700806A (en) | 1992-08-10 |
| PE17291A1 (en) | 1991-06-01 |
| DE69023135T2 (en) | 1996-06-20 |
| FI96188B (en) | 1996-02-15 |
| WO1991012910A1 (en) | 1991-09-05 |
| CN1036254C (en) | 1997-10-29 |
| BG61184B1 (en) | 1997-02-28 |
| ES2080298T3 (en) | 1996-02-01 |
| BG95154A (en) | 1993-12-24 |
| FI96188C (en) | 1996-05-27 |
| MY110424A (en) | 1998-05-30 |
| RU2081724C1 (en) | 1997-06-20 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US4493363A (en) | Method at continuous casting of steels and metal alloys with segregation tendency and apparatus for carrying out the method | |
| EP0470220B1 (en) | Process and apparatus for producing molded shapes | |
| AU2002222478A1 (en) | Treating molten metals by moving electric arc | |
| US3354937A (en) | Process and apparatus for continuous casting | |
| US5103892A (en) | Continuous casting of discrete shapes | |
| AU633154B2 (en) | Method of controlling the rate of heat extraction in mould casting | |
| US3749149A (en) | Method and an electro-beam furnace for ingot production | |
| JPH026037A (en) | Method for continuously casting steel | |
| US4287934A (en) | Continuous casting mold | |
| CA1130981A (en) | Continuous cast steel bar and the method to produce same | |
| US4022265A (en) | Method for enlarging the width of a cast piece in a continuous casting operation | |
| US3818972A (en) | Cast bar draft angle | |
| JP2911323B2 (en) | Method and apparatus for manufacturing metal ingots | |
| US4250949A (en) | Semicontinuous casting apparatus | |
| CA1196471A (en) | Semicontinuous casting process | |
| RU2020037C1 (en) | Method and device for periodic casting of metals | |
| DR Thornton BSc | Moulds for Continuous Casting | |
| JPS6227904B2 (en) | ||
| JPH01130860A (en) | Manufacture of stainless steel cast billet for forging | |
| JPS6365001A (en) | Continuous molding device | |
| JPS58224047A (en) | Method and device for continuous casting | |
| JPS6046843A (en) | Production of flat metallic plate | |
| Hulek | Plant for the Continuous Casting of Steel | |
| Pliskanovs et al. | Continuous Wide Strip Caster | |
| Dozhdikov et al. | Thermal physical characteristics of moulds for continuous casting of slabs |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Discontinued |