Aluminum Alloy Rod Continuous Casting & Rolling Line CCR line

1. Pure aluminum rod or aluminum alloy rod in dia.9.5mm 2. Tilting holding furnace 3. Rolling mill, casting, rolling machine

1. Application

Aluminum Alloy Rod Continuous Casting & Rolling Mill is used to continuously produce pure aluminum rod or aluminum alloy rod in 9.5 mm diameter conforming to EC grade standards.

2. Main Components

Shaft furnace, holding furnace, continuous casting machine, in-line refinery, oil hydraulic shears, straightener, induction heating furnace, continuous rolling mill, lubrication system, emulsion cooling system, quenching and coiler, and electric control system.

3. Brief Process Flow

Aluminum ingot melting furnace holding furnace (for mixing alloy elements) in-line refinery casting machine oil hydraulic shears induction heating furnace continuous rolling mill quenching and coiling unit aluminum alloy rod.

4. Main Technical Data

4.1. Diameter of casting wheel:         1600mm

4.2. Type of casting machine:           5-wheel construction

4.3. Cross sectional area of cast bar: 2280mm2

4.4. Type of rolling:                           two-roller + three-roller stands

4.5. Number of rolling pass:              2 + 12

4.6. Nominal diameter of roller:         255mm

4.7. Outlet diameter:                        9.5mm

4.8. Max. final rolling speed:             6.2m/sec.

4.9. Max. output:                            4.2 mt/hr.

4.10. Main motor power:                  355kW

4.11. Coiling diameter:                    1200~2000mm

4.12. Bundled weight:                       2.5 t

4.13. Total installed power:              450kW

5. Technical Data of Components

5.1.Continuous casting machine

5.1.1. Cross sectional area of cavity of casting wheel: 2300mm2

5.1.2. Type of casting wheel: H shape

5.1.3. Max. linear speed of cast bar: 18.5m/min.

5.1.4. Motor power: 4kW

5.1.5. Cooling water pressure: 0.3~0.5Mpa

5.1.6. Max. cooling water flow: 100m3/hr.

5.2.Oil hydraulic shears

5.2.1. Max. shearing force: 20000kfg

5.2.2. Max. shearing stroke: 65mm

5.2.3. Shearing speed: 1.7sec/time

5.2.4. Type of electric hoist: CD1-0.50

5.2.5. Lifting weight: 500 kg

5.2.6. Type of oil pump: CB-32

5.2.7. Motor for oil pump: Y132M-4, 7.5kW, 1440rpm

5.3.Continuous rolling machine

5.3.1. Type of rolling: two-roller + three-roller

5.3.2. Transmission ratio between two neighboring stands: 1:1.415 ~ 1:1.25

5.3.3. Central height of rolling: 900mm

5.4.Lubrication system

5.4.1. Oil tank 5m3: 1 set

5.4.2. Oil pump 2CY-12/0.33-2: 2 sets

5.4.3. Filter SLQ-50: 1 piece (twin-barrel filter)

5.5.Emulsion cooling and lubrication system

5.5.1. Emulsion pump IS100-65-200: 2 sets

         Max. flow: 100m3/hr., working pressure: 5kfg/cm2

5.5.2. Plate chiller BB0.3-1.0-45, 45m2: 1 piece

5.6. Quenching and coiling unit

5.6.1. Coiling speed: 6.5mps

5.6.2. Outlet diameter: 9.5mm

5.6.3. Coiling diameter: 1200~2000mm

5.6.4. Motor power for coiler: 3kW

5.6.5. Power of drive motor: 4kW

5.6.6. Motor for trolley: 2.2kW

5.6.7. Moving speed of trolley: 0.75mps

5.7. Melting furnace (5t/hr.): 1 set (charging mechanism included)

5.8. Holding furnace (8t): 2 sets

6. Features

The casting wheel of casting machine, H-shaped, is cooled from the inner, outer and two sides, among which, the outer and the side cooling is divided into 4 zones, the inner cooling into 6 zones. Water supply for each of them can be regulated separately with pressure gauge, which makes it a benefit for cast bar to be cooled evenly and crystal grain to be refined with high adaptability in process control. Pneumatic tensioner, with a regulator, is applied to steel tape. Once the tension is set, the steel tape keeps constant in force so as to produce aluminum alloy bar in high quality.

The continuous rolling machine is of two-roller plus three-roller type. It helps to intensify the deformation of cast bar under high temperature. The cooling and lubrication emulsion is supplied in two routes, one of which is for gears and bearings, and the other is for inlet and outlet positioning guides. The flow of the latter is regulated separately because it greatly affects the temperature of the rolled bar, making it easy for process control.

The quenching and coiling unit has in-line cooling function to ensure the temperature of the finished rod to be adjustable. The coiler is in twin-basket type.

Electrical control system: The production line, driven by DC motor, is provided with Siemens fully digital DC speed regulator in host machine and drive motor. The controller is equipped with Siemens PLC and man-machine interface screen to display parameters and fault or trouble.

                 

7. Items to be Prepared by User

7.1. Circulation system of cooling water for casting wheel of the casting machine;

Water supply system for chillers including cooling pumps, pumps for drainage, cooling tower, valves, and pipelines, etc.

7.2.  Wires and cables from the local electric power supply network, and those between the electric panels and the machines, and between the panels.

Aluminum Alloy Rod Continuous Casting & Rolling Line CCR line