Use of a Multi-sensor Technique to Monitor the Mould Oscillation in a Continuous Billet Caster

Abstract

Producing a defect free product is most important in the process of continuous casting as the defect may propagate to the end product and also can increase the downgrading. Inadequate oscillation parameters as well as a defective oscillation may greatly affect the surface quality of the cast product. So monitoring friction along with the oscillation profile of the oscillator can lead to take corrective action when there is an increase in friction between the mould and strand or if there is any wear and tear in the machine components. In the present work a multi-sensor based mould oscillation monitoring system was developed to monitor the mould health as well as the friction between the mould and strand of a billet caster. Friction force was calculated for different carbon composition, type of lubrications and was co-related with the surface quality of billets. Also monitoring the mould health was able to detect problems in the machine and corrective action could be taken care of in time.

The Shell Surface Force Caused by Mould Friction during Slab Continuous Casting

“…Moreover, inadequate powder consumption as well as a non-uniform lubrication may greatly affect the surface quality of the cast product. 4) The mould friction (MDF) between strand and mould is the most directly measurable parameter that can be used to describe strand/mould mechanical interaction and powder lubrication. 5) It is therefore necessary to reduce the friction force between the mould and the solidified shell in order to avoid the formation of defects in the solidified shell.…”

“…Various research works had been published about this topic. 1,[4][5][6][7][8][9] However, few papers are devoted to research the periodical variation of mould friction, especially for the comparison of mould friction for sinusoidal and non-sinusoidal oscillation. In view of this, the investigation of intensive measurement was carried out to determine the friction forces at a slab caster.…”

Mould oscillation monitoring with hydraulic oscillators in slab continuous casting

“…During high speed casting, inadequate oscillation parameters as well as a defective oscillation may greatly affect the surface quality of the cast product and therefore are to be considered as critical. 1 In recent years, with the drive for high speed continuous casting, much progress has been made in caster technologies, one of which is the development and widespread application of hydraulic oscillators. Hydraulically driven oscillators could offer the maximum flexibility for an online adjustment of the oscillating curves.…”

Investigation of Friction Force between Mould and Strand Shell under Sinusoidal and Non‐sinusoidal Oscillation in Continuous Slab Casting

“…Investigation of the frictional behaviour is therefore essential to obtain a better online control of the mould processes. Under the conventional sinusoidal oscillation pattern, casting at higher speed may cause a decrease in flux powder consumption, and therefore increase the friction force, worsen the surface quality and even cause sticking breakouts [1][2][3][4]. The non-sinusoidal oscillation pattern has gradually been developed and applied in mould oscillation.…”

“…Various research studies were published about non-sinusoidal oscillation theory, wave form, factor and application [4][5][6][7][8][9][10][11]. Theoretical analyses show that the features of non-sinusoidal oscillation in comparison with a sinusoidal pattern are the following: (1) As the positive strip time is longer, the rate of flux powder consumption increases and the friction force can be reduced; (2) The relative velocity of mould to the solidified shell in the positive strip period decreases, and accordingly the tension acting on the solidified shell is reduced; (3) In contrast, the relative velocity during the negative strip period increases, and the required level of the compressive force acting on the solidified shell will increase in the negative strip period. However, in some papers the research on friction force in non-sinusoidal oscillation is only in theory and insufficiently supported by measured data, and in some experimental papers the comparison of the periodical variety of friction force and some correlative parameters between the two kinds of 564 oscillation patterns is not taken into account.…”