Aluminium Alloy Casting Machine

Shanghai Lishang International Trading Co.,Ltd., the professional Aluminium Alloy Casting Machine
supplier in China, and the best continuous casting machine manufacturer in China.
1. Aluminum Casting and Rolling Machine Application:
This aluminum rod CCR line is designed to manufacture aluminum conductive rod diameter of 12mm with 13rolling stands, 9.5mm with 15 rolling stands.
2. Aluminum Casting and Rolling Machine Brief technological process:
2.1

2.2 Aluminum liquid or compounded aluminum flows from the holding furnace through the launder to the belt continuous casting machine to cast the molten aluminum into trapezium ingot with a section of 2400mm2, then shear the substandard aluminum ingot, press the front part small, and feed it into the 15 rolling stands to manufacture al. rod with a dia. of 9.5mm. The stand (can also be bought from us) which will loop it.
3. Aluminum Casting and Rolling Machine Main technical date:
Dia. of the al. rod:                             12, 9.5 mm
Production capacity:                             2.5-4.2t/h
Overall dimension:                     (l×w×h) ≈32.05×7.2×4.2m
Total weight:                       ≈60t (not include the furnace body)
Technical data for components:
3.1. Continuous casting machine
Dia. of the crystallizing wheel:                          1500mm
Section of the crystallizing wheel:                        2420mm2
Section of the ingot:                                   2400mm2
Casting speed:        7.6-15m/min (rotate speed of the motor 500-1000r/min)
Rotate speed of the crystallizing wheel:                    1.66-3.3r/min
Power of the crystallizing wheel motor:                    4Kw
Cooling water pressure of the crystallizing wheel:            0.35-0.6Mpa
Cooling water consumption:    100t/h (inner cooling 60t/h, outer cooling 40t/h)
Water pump type:                                     IS100-65-200
Motor type:                                       Y160M2-2   22Kw
3.2. Monorail hydraulic shear:
Max. shearing force:                                       12000kgf
Max. shearing stroke:                                       65mm
Motor hoist type:                             TV-0.50  Max. load 250kg
Pump type:                                              CB-FC-20
Oilpressure: 160kg/cm2
Oil volume: 20L/min
Motor power:                                     7.5Kw  n=960r/min
3.3. Continuous rolling machine type Y:
Type:                                                3-roller type Y
Dia. of rod:                                           9.5, 12mm
No. of rolling stands:                                          15, 13
Nominal roller dia.:                                         255mm
Driving ratio between neighboring stands:                         1:1.25
Max. finished rolling speed:                                  V=6.2m/s
Rolling center height:                                       852.5mm
Main motor power:                             250kw (DC n=500R/min)
Gear box and lubricating oil box:                                  3m3
3.4. Coiler:
Max. coiling weight:                                             2t
Max. dia. of the coiler:                                      1800mm
Driving motor power:                                        1.5kw
Trolley motor:                                              2.2kw
Trolley speed:                                              0.75/s
4. Aluminum Casting and Rolling Machine Component parts and structural features:
4.1. Continuous casting machine:
Belt continuous casting machine consists of crystallizing wheel, driving device, press roll device, steel belt greasing device, guide bridge, steel belt tensioner, external cooling inject, steel belt, etc.
The melt aluminum flows from the holding furnace through the launder to the pouring groove, the floating head of the plug controls the flow of the al. liquid, the liquid is poured into the cavity formed by the crystallizing wheel and the sealed belt. The whole pouring groove can be moved up and down driving by the power of motor. Worm gear reducer and screw pair. The section of crystallizing wheel is M-type, and it is driven by the motor. The crystallizing wheel is equipped with an inner cooling device, which could spray cooling water onto the inner surface of the wheel with a water pressure of 0.35 Mpa. The inner cooling water can be divided into 6 sections; the flow could be controlled by the cut off valve. The external cooling device spray the cooling water onto the steel belt, so as to cool the al. liquid won't flow out. The guide wheel is used to adjust or change the direction of the steel belt and change the length of the cavity. The tension of the steel belt can be changed through the tensioner, so as to keep a certain tension. In order to strip the al. ingot, the continuous casting machine is equipped with steel belt greasing device. Because the whole process is not interrupted long ingot can be gained.
4.2. Monorail hydraulic shear:
The monorail hydraulic shear system consists of monorail hoist, hydraulic shearing device and oil system. The max. load is 250kg. In order to make it convenient to use hydraulic shear between the space of the continuous casting machine and continuous rolling mill, the hoist can move alone the crossbeam which is 7 meters high. The max. shear force of the hydraulic shear is 12000kgf. It is mainly used for shearing the unstandardized al. ingot.
4.3. Continuous rolling mill:
The continuous rolling mill consists of 15 rolling stands of three rollers type-Y. The nominal dia. is 255mm. there are 7 upper driving device for even number rolling stands and 8 lower driving device for odd number rolling stands, they are arranged alternately. The type of the hole is "circuit-arc triangle-circuit". The main DC motor transmits the power through the coupler and the main shaft under the 12th rolling stand of driving gearbox. The transmission ratio between two neighboring stands is 1:1.25; there is safe tooth-like coupling in the junction of the gearbox and rolling stands. When it is overloaded, the safe pin will be cut to avoid the accident. In the front and the back of the rolling stands there are inlet and outlet guide device. The rolling guide device is used in the odd number rolling stands, and the sliding guide device is used in the even number rolling stands. Small roller of every rolling stands can be adjusted by shims of the different thickness; the range can be 0.1-1.00mm. The adjustment of the hole every rolling stands is taken out by a certain plug gauge. The seam can be 0.866mm, the tolerance is ±0.10mm.
The thin-oil lubricating system is used to lubricating the driving gearbox and bearings. It includes:
Oil pump:                                           ZCY-18m3/0.36
Max. flow:                                                18m3/h
Work pressure:                                            0.35Mpa
Motor type:                                       Y132M2-6   5.5kw
Oil temperature:                                            35-45oC
Oil tank:                                                     3m3
The lubricating oil comes out of the oil box which has a volume of 3m3, and flows through the oil pump into the main intake pipe and then into the gearbox in three different ways. The lubricating oil is sprayed onto the gear through the oil nozzle, and lubricates the rolling bearing directly through the red copper joint of the branch oil pipe and the upper part of the bearing block.
The emulsion comes out of the emulsion station and flows into the main emulsion pipe which is installed in the driving gear box, and flows through the top and two sides of the stands into the rolling stands and the guide device separately. The returned emulsion can flows back to the emulsion tank through the return emulsion pipe and slot.
4.4. Coiling stands:
The coiling stand consists of the coiler and the trolley and the collecting basket. The rod is guided by the guide pipe into the spinning head of the worn, and it is going to form different dia. of loop in the collecting basket. This is down by changing the rotational speed of the motor of the spinning head. By adding the lubricating grease, the frictional force between the rod and guide pipe will be reduced. This can protect the finished rod or wire.
There are two collecting basket of the same size on the trolley, and under the trolley there is a motor. When one is full, another basket is going to take its place. On the top of the coiling stand, there is a dust hood, which linked to the exhaust pipe under the pillar of coiler, so the fume produced when the rod travels through the guide pipe.
5. Installation and debugging
5.1. Bottom plate of the continuous casting machine and external cooling device of the guide bridge are installed on the base then rectify them in order to make sure the depth of the parallelism and verticality of the tensioning device and the shaft of the crystallizing wheel, the permitted error should between 0.05 to 0.10mm, then grouting for the second time.
There should be pre-moded holes for the giant bottom plate, and then put the plane at the right place, and rectify the plane, the grouting of the second time. After one week for maintenance, the bolt of the gearbox should be twisted tightly, and then install the bottom plane of the rolling stands and rectify the relative position of the gearbox and the bottom plane. After the rolling stands are installed, the pillar of the monorail shear and the emulsion station should be installed in the work place or the cellar near the workplace according to the particular situation of the factory.
5.2. After a period of maintenance check the foundation bolts then fasten the foundation bolts again. Check all the driving parts and the joints to see if they are reliable. Check the oil and emulsion pipe to make sure the inlet and outlet unblocked. And then try the machine unloaded for 2 hours. During these 2 hours, the temperature of every bearing should be checked and written down at a fix time. If there is anything unusual, the machine should be stopped and rectified at once. If the machine works regularly, it should be checked once again after it is stopped. To check the gears to see if they work well, filter of change the lubricating oil once again.
Before the continuous casting machine works loaded in different speeds, make sure that:
The position of the pouring groove and the liquid level is right;
The pressure and flow of the cooling water is appropriate;
The spray nozzle is unimpeded;
The steel belt is tensioned;
Before the continuous rolling machine works loaded with the continuous casting machine, make sure that:
The type of the holes of the rollers are suitable;
The size of the holes and the seams should be checked by technical gauge and the thickness meter;
The guide position device should be installed well;
Every oil and emulsion channel work unimpeded.
And the oil slot of the guide pipe should be filled with lubricant. If the rod doesn't come out continuously, or the guide pipe is blocked, the guide pipe can be dismantled to clear.
Before the al. ingot enters the rollers, the motor for the coiler should be started. When the rod is looped in the collecting basket, change the rotate speed manually to make sure the dia. of the loops fits the requirement. If one of the baskets is full, press the push-bottom to change the basket, meantime make sure the al. rod falls into the basket.
When this CCL stars to work, adjust the speeds of the rolling mill and the coiler according to the casting machine to realize continuous producing. There are one oil pump and water pump for spare use. When there is something wrong with the oil pump or water pump, start the spare pumps and close the according valve.
During the continuous casting machine works, pay more attention to the rate of the al. liquid flow. If the flow rate is too small, there will be hollow or cut off of the ingot, if the flow rate is too big, the edge wont be smooth, and it will block he holes of rollers. And the over-edge should be cleaned off in time.
6. Aluminum Casting and Rolling Machine General situation: electrical circuit drawing
7. Aluminum Casting and Rolling Machine Operation: training on site
8. Aluminum Casting and Rolling Machine List of the bearings
8.1. List of the bearings
No. Drawing No. Parts Specification of bearing Bearing type Quantity
1 H202-101-00 Crystallizing wheel 180/280×100 24036 1
2 H202-040-00 Guide bridge 70/125×24 6214 8
8.2. Continuous rolling mill
No. Drawing No. Parts Specification of bearings Bearing type Quantity
1 H201-101-00 Gear box 120/215×62 7524 31
150/270×45 7530 1
2 H201-020-00 Odd number roller stands 70/150×35 2314 8
60/110×30 7512 48
3 H201-030-00 Even number roller stands 70/150×35 2314 7
60/110×30 7512 42
4 H201-060-00 Input ingot press
roll 40/80×18 208 2
40/80×18 208 2
5 H201-080-00 Entry guide pipe
for odd no. stand 12/28×8 101 4
15/32×9 102 28
8.3 Coiling stand
No. Drawing No. Parts Specification of bearings Bearing type quantity
1 H203-020-00 Worm gear reducer box 100/65×18 6013 2
85/45×15 72009 1
2 H203-020-00 Trolley  55/120×29 312 4
9. Aluminum Casting and Rolling Machine Maintenance and reparation
9.1. All the places equipped with oil cup or existing relative motion, such as guide rail, screw and screw mandrel, etc. should be added with lubricating oil.
9.2. In all the lubricating oil station, emulsion stations, the oil level should be paid more attention to, and be clear at a fixed time to avoid being blocked. And lubricating oil should be added by a fixed time to keep a certain density. If they have been deteriorated, the deteriorated part should be cleared out in time. The oil should be filtered half a year, and no other dirty things are allowed to get in.
9.3. After working for 1500 hours, every gearbox should be opened and cleared, and filled in new oil, and make sure the oil level at the right place.
9.4. If the machine hasn't been used for a long time, the parts existing relative motion should be sprayed with oil. The taper gears and bearings of the rolling stands should be added with a certain volume of lubricant to avoid being rusted.
9.5. The cooling water should be supplied continuously; otherwise, the crystallizing wheel will be damaged.
9.6. If the load is added suddenly or the raw material is heap up, the shear pin of the safe coupling shaft.