Journal of

Mechanical Science and Technology

Journal of Mechanical Science and Technology 21 (2007) 421~425

Development of New Model of Mold Oscillator in Continuous Casting

G. P. Kanga,*, G. Shina, C. G. Kangb
a

POSCO, Department of Steelmaking Research Group, Pohang 790-785, Korea b Pusan National University, School of Mechanical Engineering

(Manuscript Received May 3, 2006; Revised December 5, 2006; Accepted January 17, 2007) --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

Abstract
To develop the hydraulic mold oscillator in continuous casting machine, the guiding mechanism of mold was studied. The main topics of this study were to design the guiding mechanism of mold which oscillates to prevent the sticking and to reduce the friction resistant force between the solidified shell and mold on casting. We studied many guiding types to analyze the features of worldwide mold oscillator and developed the new model of hydraulic mold oscillator. On the basis of the mold oscillating experiment, the capability of guiding system was proofed by the position error measuring system. The experiment was carried out up to 50 ~ 500 cpm frequencies and 2~10 mm stroke in the variable waveform and the casting results was analyzed by the oscillation mark of slab surface which was formed unavoidably by oscillation.
Keywords: Continuous cast, Mold, Oscillator, Guiding mechanism, Plate spring, LM guide abstract --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

1. Introduction
Over the last five years, we have elected pilot caster to develop the high speed casting technology. As we know, the continuous caster is facilities to product slab from molten steel. The quality of slab is affected by components of caster and operating technology. Mold oscillator is main facilities to solidify the molten steel and to decide the dimension of slab. Its features of product requirement to design the mold oscillator are followings. Slab width: 600 ~ 1,000 mm Slab thickness: 100, 140 mm (Two Types) Copper Length for Low Speed (2.5 mpm): 950 mm Copper Length for High Speed (5 mpm): 1,100 mm To satisfy these conditions, we developed the
*

Corresponding author. Tel.: +82 54 220 9224; Fax.: +82 54 220 6832 E-mail address: [email protected]

mechanism to adjust the centerline of narrow face of 2 types (100, 140 mm N.F) for width adjustment. And for the various technical experiments, we developed the hydraulic mold oscillator that oscillates up to 50 ~ 500 cpm frequencies and 2~10 mm stroke in the variable waveform. For the various speed range of oscillation to control the powder consumption that function as lubrication between copper plate and solidified shell of molten steel, it needs the light dynamic mechanism to counterbalance the moving weight of mold oscillator (Becker et al., 1997). So, we have adapted the plate spring and linear motion guiding device. For the decision of guiding mechanism, we had tested several guiding device that reviewed the mecha-nism of various mold oscillator in world wide. And we had tested the position error by laser sensor according to various operating conditions of waveforms and asymmetry factor and frequency. To design the hydraulic power unit and equipment for oscillation, we had calculated the driving force and velocity by dynamic analysis that had been

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needed to operate the oscillator over the limit condition. To review the performance of mold oscillator, we have analyzed the oscillation mark depth and hook of slab surface produced through various casting speed (Becker et al., 1997).

2. Calculations for basic design

To calculate the technical data for mold oscillator, we had studied the driving force that had been needed to oscillate the moving part of mold oscillator.
Fig. 1. Profile comparison of waveform velocity.

2.1 Driving force of mold oscillator 1) Moving mass: 180,000 N 2) Operating load condition Dynamic Load = 3g Mass = 529,740 N Internal mold friction = Normal force Friction factor = 73,804 N Normal Force =
1 2

2.3 Operating condition of mold oscillator Maximum driving force condition is occurred in the stage of upstroke due to gravity. And all dynamic features like as force and velocity and acceleration are affected by the asymmetry of waveform and the oscillating stroke and frequency. Asymmetry: 30 ~ 70% Stroke: 1~10 mm Frequency: 50 ~ 500 cycle/min From the above basic data, hydraulic specification had been calculated. Hydraulic pressure is calculated by maximum driving force and acceleration. And hydraulic flow rate is calculated by maximum velocity. Then hydraulic cylinder dimension is decided by pressure and force needed and push rod dimension considered by buckling.

gh Peripheral Length

EMBR viscous damping force (not used here) 3) Driving Force by 2 hydraulic cylinders .1 Cylinder force = (Load + Friction force)/2 =301,772 N 2.2 Waveform review of mold oscillator There are 4 types waveform for oscillation like as sinusoidal, non-sinusoidal, triangle, double sinusoidal waveform. Non sinusoidal waveform is modified by asymmetry (Becker et al., 1997 ; Darle et al., 1993)to control the velocity of up and down stroke from the following sinusoidal waveform 1) Sinusoidal waveform review
Displacement : d (t ) = h * sin( t A * sin( t + sin( t ))) Velocity : v(t) = h * * cos( t A * sin( wt + * sin( t ))) *(1 A * (1 + * cos( t )) * cos( t + * sin( t ))) Acceleration : 2 a (t ) = h * * (A*cos( t - A*sin( t + *sin( t)))

3. Guiding mechanism of mold oscillator

Moving part of mold oscillator is constrained to move into up down side, so guiding mechanism is need to support the vertical motion and to prevent the horizontal motion. The performance of guiding mechanism is decided by the horizontal motion error and the abrasion feature and the duration of operation. 3.1 Review of the existing mechanism

*( *cos( t + *sin( t))*sin( t) + (1 + *cos( t)) *sin( t + *sin( t))) - (-1 + A*(1 + *cos( t))*cos( t + *sin( t)) *sin( t - A*sin( t + *sin( t))))

We reviewed the 3 types of guiding mechanism on operating and draw out of new guiding mechanism like as the linear motion guide (LM guide). 3.2 Experiment of guiding mechanism To test guiding mechanism in the above operating condition, we had decided specification of the LM

Here, and A are asymmetry factor. 2) Velocity comparison of waveform

(~ P K,~n~ ~'t ~I

.h..~r.a/~- ~,[c'ch~..cal .r

dng 7~,,"hno,~gv ?/COO 72 4~t 423

423

Fig. 2 Guidin~ tned~anism I}pcs d,M Stride, P,otler. I'latr ~.pnngl

Fig. 3, ll~c scl~crnalic diagram o l ' [ M guide i~sl~tllatiol+

Fig. 5. Case ~lud} ~l'pli0.c sprillg lablc i. Malturia~lpmpcrb Ibr amLhsis.

Material '~'om~g's Penis.son's [)cTtsit~ _A.lh;~vcd Moduhls " k;trcllet}'~ (kg...mm.s~) Ratio (kg,'mm :) (k~;mm.s~)

SM4(}() 2.tlN'txI0~ S IJP9

Fig. 4. lns~,~.lllaliortslak,n im,,l the; d~;to,d~:li;q ~1 b~lil I) p',: [.M guide.

0,3 0,275

7.85

~'

2.35x 10~ 1_57I0"

7.848 I(17

7.85 10"'

guide through calculation of lhe following schematic diagram. We experiment the LM guide ~,ype for 1 year and analyzed the duration of LM guide, i:irgt, the ball type L M guide showed the denlh~g defect oil surface of guide rail alter 2 months, Second. the roller type LM guide had been operated fbr I year and then dismantled to analyze the abrasion status. It showed good per[brmance and we decided to adapt the plate spring that support the counterbalancing weight and resist to structure vibration.

Fig. 6. Sin:s:, disuibulion olca~c ~.md,. I(t alld 5 plm.csL

&3 C~l.~'e.~'tudy ~ u i d b ~ R mechanA.~'mhy phste.sl~flnR

To use the plate spring by the ~uiding mechanism. ~e had re~'ie~ed ;he deformation of plate spring. In the progre~.sing stage of basic design, we decided to study the deFormalion analysis of pine spring rather than calculation by manual. To decide the dimension of plate spring, we analyzed the three case combinNion oF plate spring.
Fig, 7, Sires', distribution ol'canc ~,t~l(l_~2(| arid 5 plaice} Fhe analyzing input condition was _3 m m down stroke ill the end o f plate and it had been compared each o(hers by i'naxJrnLinl S[reSS occtln'r [Park et al 3.

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G. P. Kang et al. / Journal of Mechanical Science and Technology 21(2007) 421~425

We decided case 1 for safety and counterbalance and adapted the double plates separated by the shim plate between each plate. 3.4 Operating Result of guiding mechanism From the case study, we had decided the guiding mechanism of pilot caster as following Fig. 9.

Fig. 10. Measurement configuration of oscillation error.

Fig. 8. Stress distribution of case study 3(1 and 5 plates). Table 2. Results of case study.

Type 1 1 2 2 3 3

Pieces 1 5 1 5 1 5

Maximum Stress (kg/mms2) 5.34 104 6.22 105 5.82 104 2.15 106 5.62 104 1.10 106

Fig. 11. Measurement results of position error.

Fig. 9. Configuration of the guiding mechanism.

Fig. 12. Measurement results of phase error.

We had experiment the position error by laser displacement sensor like as following Fig. 10. And position error is tested in the range of operating frequency and stroke (Fig. 11). And we checked the limit condition by the abnormal vibration of structure.

mold and experiments have been performed to reduce the friction resistant force between the solidified shell and mold during continuous casting process. The guiding performance was improved by the adoption of plate spring and LM guide. In Fig. 11 and Fig. 12, the result of operation shows that position error become worse according to the higher frequency and the bigger stroke. Because the stroke loss defends on the operating condition, to guarantee the position

4. Conclusion
To develop the hydraulic mold oscillator in continuous casting machine, the guiding mechanism of

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precision, oscillation should be operated in the hydraulic operating range. In the Fig.12, The Vertical position error (0.2 mm) that means phase error makes the horizontal error (0.03 mm) and should be calibrated through the pitch measurement between foot roll and segemnt.

Nomenclature ---------------------------------------------------------A: Asymmetry Value : Asymmetry factor

References
Becker, E. H., Wyl, H. von, Lohse, D. A., Bunsen, Ch.,

1997, Resonance Mould System in Continuous Casting, Ironmaking and Steelmaking, Vol.24, No.2, pp. 174~178. Darle, T., Mouchette, A., Nadif, M., Roscini, M., Salvadori, D., 1993, Hydraulic Oscillation of the CC slab mold at SOLLAC FLORANGE: First Industrial results, future developments, Steelmaking Conference Procee-dings, pp. 209~218. Cassels, I., Tolputt, T., 1998, Advanced mould design for slab casting, Steel Times/Steel Times International, September, CC18. Park, Y. T., Lee, C. S., Hwang, W., Kang, G. P., Shin, G., Robust Design of the Mold Oscillator of Continuous Casting Machine, Proceedings of the Korean Society of Precision Engineering Conference, pp.782~ 785.