Experimental Researches of Working Parameters of Spiral Screws for Dispensing of Slagging Mixtures in Molds of Continuous Casting Machines

The time of information technology determines its priorities, which are a prerequisite for building a competitive production and economy. The ubiquitous spread of digitalization is one of the basic principles of new economy, a new type of socio–economic structure that is gradually being formed in the modern world through the introduction of scientific and technological progress and innovative methods of management, intellectualization and capitalization of human knowledge, the use of advanced new information and material technologies, accelerated development of knowledge-intensive sectors of the economy, the formation of creative, efficient, rational information and material production. Currently, at large foundries with mass and large-scale production of castings, the task of automating the control of technological processes using digital control systems was solved in general. They implement algorithms for controlling technological processes of casting in closed circuits (locally). The systems under consideration allow to implement optimal control strategies and automatically perform sequences of operations (start and stop of equipment; calculation and input of metal charge; calculation of formulations, dosing and mixing of molding and core mixtures) of multi-stage periodic casting processes. Digital transformation can significantly change the established practice of foundry production (from direct control and management of technological processes to business planning and document management). The transformation will have an impact on all parameters of the enterprise: economic efficiency of production (productivity, operating costs); reliability (operational readiness); safety (number of incidents); compliance with legislative norms on ecology. The technological criterion for success of the digital transformation of foundry production will be the release of a nomenclature of castings with a minimum level of defect, commercial – the release of a nomenclature of castings in demand on the market (machine parts and mechanisms), with a minimum self-cost, which is determined by the technological level of preparation of the production and its implementation and, as a consequence, low costs and optimal quality of molds, metal and castings.

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Prospects and directions of digital transformation in foundry

Knyazev

Kutsenko

Усольцев

et al. 2023

Izv. vysš. učebn. zaved., Čern. metall.

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An experience of elaboration and implementation of systems of slag-forming mixtures mechanized feeding into CCM moulds

Eron’ko¹,

Ткачев²,

Ошовская³

et al. 2020

Černaâ metallurgiâ. Bûlletenʹ naučno-tehničeskoj informacii

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Effective application of slag-forming mixtures (SFM), being fed into continuous castingg machine (CCM) moulds, depends on their even distribution on the melt surface. Manual feeding of the SFM which is widely usedd does not provide this condition, resulting in the necessity to actualize the work to elaborate systems of SFM mechanized feedingg into moulds of various types CCM. A concept of the designing of a system of SFM feeding into CCM moulds presented with the ratte strictly correspondent to the casting speed and providing formation of an even layer of fine material of given thickness on the whoole surface of liquid steel. The proposed methods of designing of the SFM mechanized feeding systems based on three-dimensional computer simulation with the subsequent verification of the correctness of the adopted technical solutions on field samples. Informattion is presented on the design features of the adjusted facilities intended for continuous supply of finely granulated and powder mixtuures on metal mirror in moulds at the production of high-quality billets, blooms and slabs. Variants of mechanical and pneumo-mechaanical SFM supply elaborated. At the mechanical supply the fine material from the feeding hopper is moved at a adjusted distance bby a rigid horizontally located screw. At the pneumo-mechanical supply the metered doze of the granular mixture is delivered by a sshort vertical screw, the lower part of which is located in the mixing chamber attached from below to the hopper and equipped with ann ejector serving for pneumatic supply of the SFM in a stream of transporting gas. It was proposed to use flexible spiral screws in the ffuture facilities of mechanical SFM feeding. It will enable to eliminate the restrictions stipulated by the lack of free surface for locatiion of the facility in the working zone of the tundish, as well as to decrease significantly the mass of its movable part and to decreaase the necessary power of the carriage moving mechanism driver. The novelty of the proposed technical solutions is protected by thhree patents. The reduction of 10–15% in the consumption of slag-forming mixtures during the transition from manual to mechanizeed feeding confirmed. The resulting economic effect from the implementation of technical development enables to recoup the costs inncurred within 8–10 months.

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An automated system development to control the device for supplying slag-forming mixture into mould of CCM

Litsin

Utyamishev²

2021

Černaâ metallurgiâ. Bûlletenʹ naučno-tehničeskoj informacii

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The mechanism of feeding slag-forming mixture (SFM) with a pneumatic drive has a number of disadvantages associated, in particular, with the uneven supply of the mixture into mould. To eliminate the drawbacks, mixture feeding device with an electric drive was designed to eliminate them. In order to ensure control of the SFM feeding process, an automated system has been developed that provides real-time information on the technological process of feeding the mixture into the mould of continuous casting machine, including speed of rotation of screw drive motors and movement of carriage, the level of the mixture in the bunkers and its consumption, temperature of the metal and slag. A software and hardware complex (SCADA-system) has been developed, which makes it possible to analyze the components of the mixture in the “online” mode and take into account the effect of changes in the supply of each of them on its composition. The dependence of the mixture consumption rate on the casting rate has been established, which can be displayed on the screen in the current mode. Application of the SCADA-system made it possible to control the developed SFM feeder both in manual and automatic modes. It was shown that the implementation of the developed automated SFM feeding device in the steelmaking production of Ural Steel, JSC will secure decreasing the SFM consumption by 2.8% and decreasing downtime by 5% due to increasing efficiency of fault detection with a total implementation cost of 200 thous. rubles.

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Experimental Researches of Working Parameters of Spiral Screws for Dispensing of Slagging Mixtures in Molds of Continuous Casting Machines

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Prospects and directions of digital transformation in foundry

Prospects and directions of digital transformation in foundry

An experience of elaboration and implementation of systems of slag-forming mixtures mechanized feeding into CCM moulds

An automated system development to control the device for supplying slag-forming mixture into mould of CCM

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