Understanding the Relationship between Casting Speed, Steel Plate Specifications, and Cooling Water Volume

 

Influence of Casting Speed: The casting speed determines the residence time of the casting blank in the mold. When the casting speed is relatively high, the casting blank stays in the mold for a short time. To ensure that the shell has sufficient thickness and strength, the molten steel needs to be cooled more quickly, so the cooling water volume should be appropriately increased. For example, when producing a relatively thin steel plate (such as a thickness of 10mm) and the casting speed reaches 1.5m/minute, compared with the situation where the casting speed is 1m/minute, it may be necessary to increase the cooling water volume by [X] cubic meters/hour to accelerate the solidification speed of the molten steel and prevent the shell from being torn.

 

Influence of Steel Plate Specifications: The thickness and width of the steel plate have different requirements for the cooling water volume. A thicker steel plate requires more heat transfer to complete solidification, so a larger cooling water volume is needed. For example, for a 20 - mm - thick steel plate, compared with a 10 - mm - thick steel plate, because its solidification time is longer, to ensure uniform solidification in the entire thickness direction, it may be necessary to increase the cooling water volume by about [X] cubic meters/hour. When the width of the steel plate increases, the contact area between the mold and the molten steel increases, and the heat dissipation speeds up, so it may also be necessary to adjust the cooling water volume appropriately.

 

Establishing Theoretical Models and Empirical Formulas for Adjusting Cooling Water Volume

 

Basis of Theoretical Model: Starting from the principle of heat conduction, during the cooling process of the mold, heat is transferred from the molten steel to the mold wall and then taken away by the cooling water flow. According to Fourier's law (, where is the heat flow rate, is the thermal conductivity, is the heat - transfer area, and is the temperature gradient), the cooling water volume is related to the heat flow rate. In the mold, the heat flow rate is related to factors such as the temperature of the molten steel, the thickness of the shell, and the casting speed.

 

Example of Empirical Formula Derivation: In actual production, through a large number of experiments and data accumulation, some empirical formulas can be obtained. For example, for a specific steel grade and mold type, the cooling water volume (cubic meters/hour) may have the following relationship with the casting speed (m/minute) and the steel plate thickness (mm): , where and are coefficients determined through experiments. Suppose that for a certain production line, and . When the casting speed is 1.2m/minute and the steel plate thickness is 15mm, the calculated cooling water volume cubic meters/hour.

 

Real - time Adjustment with the Help of Monitoring Equipment and Tools

Application of Temperature Sensors: Install temperature sensors on the mold wall and the surface of the casting blank to monitor temperature changes in real - time. When the temperature sensor detects that the temperature of the mold wall is too high, it indicates that the cooling water volume may be insufficient and needs to be increased; conversely, if the temperature is too low, it may be necessary to appropriately reduce the cooling water volume. For example, if the temperature at a certain position of the mold wall is 5℃ higher than the normal set value, it can be adjusted according to the predetermined adjustment rule (such as increasing the cooling water volume by 0.5 cubic meters/hour each time), and then the temperature change situation is observed.

Auxiliary Adjustment of Shell Thickness Detection: Use non - contact detection methods such as electromagnetic ultrasonic to measure the shell thickness. If the shell thickness is less than the expected value and the casting speed is normal, it may be that the cooling water volume is insufficient and the cooling water volume needs to be increased to accelerate the solidification speed so that the shell thickness meets the requirements. For example, during the production process, it is found that the shell thickness is 2mm thinner than the target thickness. By adjusting the cooling water volume (such as increasing it by [X] cubic meters/hour), the solidification conditions are improved to make the shell thickness meet the standard.

 

 

 

NK/K F43 extraStrength Chemical Composition
Grade	The Element Max (%)
	C	Si	Mn	P	S	Al	N
NK/K F43	0.18	0.55	1.60	0.025	0.025	-	0.020
	Nb	V	Ti	Cu	Cr	Ni	Mo
	-	-	-	-	-	-	-

 

Correlation of Mold Vibration Parameters: The vibration parameters of the mold (such as vibration frequency, amplitude, etc.) are related to the casting speed and the cooling water volume. Appropriate vibration parameters help to separate the shell from the mold wall and prevent adhesion. When the vibration parameters change, it may be necessary to adjust the cooling water volume accordingly. For example, when the vibration frequency of the mold is increased, the separation effect of the shell and the mold wall is better, but it may affect the cooling effect. At this time, it is necessary to fine - tune the cooling water volume according to the actual situation.

 

 

 

 

 

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