CONTINUOUS-CURVATURE CONVEX ROLL FOR CONTINUOUSLY CASTING BLOOM, AND MANUFACTURING METHOD THEREFOR

Abstract

Disclosed are a continuous-curvature convex roll for continuously casting a bloom, and a manufacturing method therefore, belonging to the field of metal casting. An outer contour curve of a working portion of a body of the continuous-curvature convex roll consists of a first straight-line segment (AB), a first transition curve segment (BC), a intermediate straight-line segment (CD), a second transition curve segment (DE) and a second straight-line segment (EF). The first transition curve segment (BC), the first straight-line segment (AB), and the intermediate straight-line segment (CD) have continuous first-order derivatives, continuous second-order derivatives, and continuous curvatures, thus forming a first transition curve with a continuous curvature. The first transition curve segment (BC) and the second transition curve segment (DE) are mirror-symmetrical. The continuous-curvature convex roll manufactured according to the technical solution can uniformly deform a blank cast in a deformation area, thereby reducing cracks. The transition curve of the convex roll can be reduced, thereby being capable of further reducing a rolling pressure and the withdrawal resistance. The present invention can be widely used in the field of metal casting.

Claims

1. A method of manufacturing a continuous curvature convex roll for a continuous casting bloom, wherein: an outer profile curve of a working part of a roll body of the continuous curvature convex roll body is composed of a first straight line section (AB), a first transition curve section (BC), an intermediate straight line section (CD), a second transition curve section (DE), and a second straight line section (EF); wherein the first transition curve section (BC), the first straight line section (AB), and the intermediate straight line section (CD) have first-order derivative continuity, second-order derivative continuity, and curvature continuity, forming a first transition curve having a continuous curvature; wherein the second transition curve section (DE), the intermediate straight line section (CD) and the second straight line section (EF) have first-order derivative continuity, second-order derivative continuity, and curvature continuity, forming a second transition curve having a continuous curvature; wherein the first transition curve (BC) and the second transition curve (DE) are mirror symmetrical; wherein when manufacturing and processing the convex roll, a blank is first cast according to shape and size requirements of the convex roll, and then the working part of the roll body is formed by subjecting the blank to rotational processing along a central axis (O.sub.1O.sub.2) of the convex roll according to a shape of the outer profile curve to form the continuous curvature convex roll; alternatively, for an existing flat roll, a protuberance is first formed on the flat roll at a position corresponding to the working part of the roll body by resurfacing welding, and then the working part of the roll body is formed by subjecting the protuberance to rotational processing along a central axis (O.sub.1O.sub.2) of the convex roll according to a shape of the outer profile curve to form the continuous curvature convex roll.

2. The method of manufacturing a continuous curvature convex roll for a continuous casting bloom according to claim 1, wherein the method of forming the first and second transition curve sections having a continuous curvature is as follows: establishing a coordinate system, wherein an origin of coordinates (0, 0), a central point (L/2, H) and an end point (L, 0) are set; generating a convex curve passing through the origin, central point and end point, wherein the origin and the end point meet second-order derivative continuity, the central point meets first-order derivative continuity, L is a sum of projection lengths of the first and second transition curves on the x axis, and H is a height of the protuberance of the convex roll; wherein the convex curve is a curve that is axisymmetric about a vertical line passing through the central point, the first curve section (OA) is a left half of the curve, and the second curve section (AB) is a right half of the curve; and wherein the first curve section (OA) serves as the first transition curve section; and the second curve section (AB) serves as the second transition curve section.

3. The method of manufacturing a continuous curvature convex roll for a continuous casting bloom according to claim 2, wherein the convex curve is depicted by equation: $y=-\frac{64H}{L^6}{x}^6+\frac{192H}{L^5}{x}^5-\frac{192H}{L^4}{x}^4+\frac{64H}{L^3}{x}^3.$

4. A continuous curvature convex roll for a continuous casting bloom, wherein: an outer profile curve of a working part of a roll body of the continuous curvature convex roll body is composed of a first straight line section (AB), a first transition curve section (BC), an intermediate straight line section (CD), a second transition curve section (DE), and a second straight line section (EF); wherein the first transition curve section (BC), the first straight line section (AB), and the intermediate straight line section (CD) have first-order derivative continuity, second-order derivative continuity, and curvature continuity, forming a first transition curve having a continuous curvature; wherein the second transition curve section (DE), the intermediate straight line section (CD) and the second straight line section (EF) have first-order derivative continuity, second-order derivative continuity, and curvature continuity, forming a second transition curve having a continuous curvature; wherein the first transition curve (BC) and the second transition curve (DE) are mirror symmetrical.

5. The continuous curvature convex roll for a continuous casting bloom according to claim 4, wherein in a coordinate system, an origin of coordinates (0, 0), a central point (L/2, H) and an end point (L, 0) are set; and a convex curve passes through the origin, central point and end point, wherein the origin and the end point meet second-order derivative continuity, the central point meets first-order derivative continuity, L is a sum of projection lengths of the first and second transition curves on the x axis, and H is a height of the protuberance of the convex roll; wherein the convex curve is a curve that is axisymmetric about a vertical line passing through the central point, the first curve section (OA) is a left half of the curve, and the second curve section (AB) is a right half of the curve; and wherein the first transition curve section is configured according to the first curve section (OA); and the second transition curve section is configured according to the second curve section (AB).

6. The continuous curvature convex roll for a continuous casting bloom according to claim 5, wherein the convex curve is depicted by equation: $y=-\frac{64H}{L^6}{x}^6+\frac{192H}{L^5}{x}^5-\frac{192H}{L^4}{x}^4+\frac{64H}{L^3}{x}^3.$

Description

DESCRIPTION OF THE DRAWINGS

[0033] FIG. 1 shows schematically a profile of a convex roll according to the present disclosure;

[0034] FIG. 2 shows schematically a coordinate system built in the horizontal cross section of the protuberance according to the present disclosure.

DETAILED DESCRIPTION

[0035] The present disclosure will be further illustrated with reference to the accompanying drawings and the following Examples.

[0036] The object of the present disclosure is to provide a soft reduction roll capable of sufficiently reducing defects generated in the surface of a rolled material.

[0037] To achieve the above object, the disclosure utilizes the following technical solution:

[0038] as shown by FIG. 1, the profile curve of the working part of the roll body of the continuous curvature convex roll body according to the present disclosure is composed of a first straight line section AB, a first transition curve section BC, an intermediate straight line section CD, a second transition curve section DE, and a second straight line section EF.

[0039] The first transition curve section BC, the first straight line section AB, and the intermediate straight line section CD have first-order derivative continuity, second-order derivative continuity, and curvature continuity.

[0040] Similarly, the second transition curve section DE, the intermediate straight line section CD and the second straight line section EF have first-order derivative continuity, second-order derivative continuity, and curvature continuity.

[0041] The method of forming the first transition curve having a continuous curvature is as follows:

[0042] establishing a coordinate system as shown by FIG. 2 (wherein an origin of coordinates is positioned at a middle point O, points O and B meet second-order derivative continuity, and point A meets first-order derivative continuity).

[0043] In this technical solution, a curve equation of the protuberance of the convex roll depicts a curve that is axisymmetric about the central point A, a curve section OA is a left half of the curve, and a curve section AB is a right half of the curve. The curve section OA serves as a left half curve of the protuberance, the curve section AB serves as a right half curve of the protuberance, and they are connected with a horizontal straight line therebetween.

[0044] The curve equation of the first transition curve of the convex roll protuberance is obtained by the following steps:

[0045] The restrictions are as follows:

[00004]$\begin{array}{cc}\mathrm{Point}\text{O}\text{:}x=\text{0:}& \\ y=0;& \left(1\right)\\ \frac{dy}{dx}=0;& \left(2\right)\\ \frac{d^{2}y}{{\mathrm{dx}}^2}=0;& \left(3\right)\\ \mathrm{Point}\text{A}\text{:}x=L/\text{2:}& \\ y=H;& \left(4\right)\\ \frac{dy}{dx}=0.& \left(5\right)\\ \mathrm{Point}\text{B}\text{:}x=\text{L}\text{:}& \\ y=0;& \left(6\right)\\ \frac{dy}{dx}=0;& \left(7\right)\\ \frac{d^{2}y}{{\mathrm{dx}}^2}=0;& \left(8\right)\end{array}$

[0046] That is, there are a total of 8 restrictions.

[0047] Assuming that the transition curve of the protuberance is in polynomial form, as there are 8 restrictions, there should be:

[00005]$\begin{array}{cc}y=a_7{x}^7+a_6{x}^6+a_5{x}^5+a_4{x}^4+a_3{x}^3+a_2{x}^2+a_{1}x+a_0& \left(9\right)\\ \frac{dy}{\mathrm{dx}}=7a_7{x}^6+6a_6{x}^5+5a_5{x}^4+4a_4{x}^3+3a_3{x}^2+2a_{2}x+a_1& \left(10\right)\\ \frac{d^{2}y}{{\mathrm{dx}}^2}=42a_7{x}^5+30a_6{x}^4+20a_5{x}^3+12a_4{x}^2+6a_{3}x+2a_2& \left(11\right)\end{array}$

[0048] The restrictions of Formulas (1)-(8) are input into Formulas (9), (10), (11), and a system of linear equations in eight unknowns is solved to obtain:

[00006]$a_0=0;a_1=0;a_2=0;$$a_3=\frac{64H}{L^3};a_4=-\frac{192H}{L^4};a_5=\frac{192H}{L^4};a_6=-\frac{64H}{L^6};a_7=0.$$y=-\frac{64H}{L^6}{x}^6+\frac{192H}{L^5}{x}^5-\frac{192H}{L^4}{x}^4+\frac{64H}{L^3}{x}^3$

[0049] This curve has a continuous curvature because of its zero-order, first-order and second-order derivative continuity. Hence, it is a smooth curve.

[0050] The above second transition curve DE can be formed as a mirror image of the first transition curve BC about a center line passing through the midpoint of the intermediate straight line section CD.

[0051] The beneficial effects of using the technical solution of the present disclosure are:

[0052] According to the present technical solution, the convex roll is used to control the soft reduction at the solidification end, and it is used comprehensively to reduce the center porosity, so as to increase the center density of the cast bloom, and improve the internal quality of a rolled material (large volume shrinkage of a casting bloom will occur during solidification of the casting bloom, so a larger reduction is needed to compensate for the volume shrinkage of the casting bloom. During the reduction process, deformation resistance will be introduced in the casting bloom, and it will be mainly concentrated in the solidified shells on both sides).

[0053] When the convex roll of the present disclosure is used to implement a heavy reduction process at the solidification end, the solidified bloom shells on both sides are prevented from generating large deformation resistance, and the heavy reduction can be applied to the middle part of the casting bloom to increase the center density of the casting bloom.

[0054] At the same time, due to the small contact area between the convex roll and the casting bloom, the friction is reduced, so the withdrawal resistance is also reduced in the continuous casting process of the casting bloom.

[0055] In addition, as a key point, when the continuous curvature convex roll manufactured using the present technical solution is operated in a soft reduction mode, the convex roll can uniformly deform the casting bloom in the deformation zone and reduce the occurrence of cracking. The transition curve of the convex roll manufactured according to the present disclosure may be shortened, which can further reduce the rolling pressure and withdrawal resistance.

[0056] In the implementation according to the present disclosure, a blank is first cast according to shape and size requirements of the convex roll of the present disclosure, and then the working part of the roll body is formed by subjecting the blank to rotational processing along a central axis O.sub.1O.sub.2 according to a shape of the outer profile curve shown by FIG. 1 to form the continuous curvature convex roll. For an existing flat roll, a protuberance is first formed on the flat roll at a position corresponding to the working part of the roll body by resurfacing welding, and then the working part of the roll body is formed by subjecting the protuberance to rotational processing along a central axis O.sub.1O.sub.2 according to the shape of the outer profile curve shown by FIG. 1 to form the continuous curvature convex roll.

EXAMPLES

[0057] For the aforementioned first straight line section AB, third straight line section EF, intermediate straight line section CD, first transition curve BC, and second transition curve DE, where possible, they are referred to using the letters at the beginning and end of the line sections to facilitate the concise description of the text.

Example 1

[0058] In the coordinate system shown by FIG. 2 (the origin of coordinates was positioned at the middle point O, the two points O and B met second-order derivative continuity, and point A met first-order derivative continuity), the length of the working roll body of the roll was 500 mm; the length of the two straight line sections was AB=EF=135 mm; the length of the intermediate straight line section CD was 150 mm; the projection length of the transition curves BC and DE on the x axis was 40 mm; the height of the protuberance was H=20 mm; and the curve equation of the transition curve BC was:

y=−4.882813×10.sup.−9x.sup.6+1.171875×10.sup.−6x.sup.5−9.375×10.sup.−5x.sup.4+2.5×10.sup.−3x.sup.3

[0059] The second transition curve DE was formed as a mirror image of the first transition curve BC about a center line passing through the midpoint of the intermediate straight line section CD.

Example 2

[0060] In the coordinate system shown by FIG. 2, the length of the working roll body of the roll was 500 mm; the length of the two straight line sections was AB=EF=115 mm; the length of the intermediate straight line section CD was 150 mm; the projection length of the transition curves BC and DE on the x axis was 60 mm; the height of the protuberance was H=20 mm; and the curve equation of the transition curve BC was:

y=−4.286694×10.sup.−10x.sup.6+1.543210×10.sup.−7x.sup.5−1.851852×10.sup.−5x.sup.4+7.407407×10.sup.−4x.sup.3

[0061] Similarly, the transition curve DE was formed as a mirror image of the transition curve BC about a center line passing through the midpoint of the line section CD.

[0062] The rest was the same as Example 1.

Example 3

[0063] In the coordinate system shown by FIG. 2, the length of the working roll body of the roll was 500 mm; the length of the two straight line sections was AB=EF=115 mm; the length of the intermediate straight line section CD was 150 mm; the projection length of the transition curves BC and DE on the x axis was 60 mm; the height of the protuberance was H=30 mm; and the curve equation of the transition curve BC was:

y=−6.430041×10.sup.−10x.sup.6+2.314815×10.sup.−7x.sup.5−2.777778×10.sup.−5x.sup.4+1.111111×10.sup.−3x.sup.3

[0064] Similarly, the transition curve DE was formed as a mirror image of the transition curve BC about a center line passing through the midpoint of the line section CD.

[0065] The rest was the same as Example 1.

Example 4

[0066] In the coordinate system shown by FIG. 2, the length of the working roll body of the roll was 500 mm; the length of the two straight line sections was AB=EF=135 mm; the length of the intermediate straight line section CD was 150 mm; the projection length of the transition curves BC and DE on the x axis was 40 mm; the height of the protuberance was H=15 mm; and the curve equation of the transition curve BC was:

y=−3.6621096×10.sup.−9x.sup.6+8.789063×10.sup.−7x.sup.5−7.031250×10.sup.−5x.sup.4+1.875000×10.sup.−3x.sup.3

[0067] Similarly, the transition curve DE was formed as a mirror image of the transition curve BC about a center line passing through the midpoint of the line section CD.

[0068] The rest was the same as Example 1.

[0069] The profile curve of the working part of the body of the convex roll manufactured according to the technical solution of the present disclosure has first-order derivative continuity, second-order derivative continuity, and curvature continuity.

[0070] The continuous curvature convex roll manufactured according to the inventive technical solution can uniformly deform the casting bloom in the deformation zone and reduce the occurrence of cracking. The transition curve of the continuous curvature convex roll may be shortened, which can further reduce the rolling pressure and withdrawal resistance.

[0071] The disclosure can be widely applied in the field of metal casting.