Aluminium Continuous Casting Machine

Shanghai Lishang International Trading Co.,Ltd., the professional continuous casting machine supplier in China, and the best continuous casting machine manufacturer in China.
1. Aluminium Continuous Casting and Rolling Machine Brief technological process:
1.1

1.2 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.
2. Aluminum Continuous 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.
3. Aluminium Continuous Casting 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. Maintenance and reparation:
4.1. 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.
4.2. 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.
4.3. 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.
4.4. 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.
4.5. The cooling water should be supplied continuously; otherwise, the crystallizing wheel will be damaged.
4.6. If the load is added suddenly or the raw material is heap up, the shear pin of the safe coupling shaft.
5. Aluminium Continuous Casting Machinery Component parts and structural features:
5.1. 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 wont 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.
5.2. 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.
5.3. 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.
5.4. 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.