Hop top billet casting machine for window and door profile
manufacturing
Process Description
Casting process starts after refining and holding of aluminium
alloy’s molten metal.
Poured out from the furnace sprout, the molten metal flows through
launder, filtered by ceramic foam filter (CFF), and then enters the
casting table where the casting moulds are fixed on. When the
casting is finished, the casting table is 90° tilted with the
moulds, and then the billets can be lifted up by suspending tools.
Technical Parameters
Casting machine is trackless steel wire rope type; It adopts
frequency control, adjusting speed between 60～850mm/min.It can move
up / down either inching or automatically. Digital displays the
speed, casting length, inlet cooling water temperature and molten
metal temperature, there is audible alarm when reaching the end of
casting and safety stop before bottom casting table coming up to
position.
It adopts single-coil, four-steel-wire-rope; the winch is equipped
with manual descending device & spring aid starting device.
Electrics for controlling for the winch & hydraulic system are set
in an electric control cabinet.
Casting pit frame is of 25# channel steel and steel sheet. Four
main pulleys of the winch are installed at four inner corners of
the casting pit frame, and tilting pedestal & cylinders are
installed on its outer rims. Upper plate of the top casting table
is 25mm thick, bottom one is 14mm, which is welded with steel
plates of 12mm thick.
Hydraulic flat-form laterally turns 90°. Tilting mechanism is
operated by hydraulic system. Hydraulic cylinders and pumps are
made in China, and main hydraulic valves are made by Yuken. Rotary
joint & connector of the water inlet are installed beside the
cylinders.
Casting pit dimension: to be determined.
Billet casting length: 6300mm, casting capacity per batch: 10t/ 15t
φ178 ± 1mm × 24pcs (10.15t)
φ178 ± 1mm × 36pcs (15.23t)
Material of launder lining, filter box lining, thimble &
distribution board is “Zhongnai No. 1”. Outer side of launder and filter box are made of steel;
filter plate size is 20 inches.
Parameters
| Rated lifting capacity | 5-60 tons |
| Lifting height | 4 to 12 meters |
| Casting size range | 4-26 inches |
| Lifting speed | 30 to 800mm/min infinitely adjustable, with manual descent device |
| Working conditions | Intermittent start-up |
| Application | Aluminum ingot or/ and billet casting, aluminum liquid transfer |
| Shafe model | 6210 |
| Main slider groove | ф20mm steel wire rope groove |
| Hydraulic tilt arm | welded by 25mm steel plate |
| Bottom material | 250*100*10 square pipes and 25mm steel plates |
FAQ
1. What are the key points of daily inspection?
Aluminum liquid temperature/level, flow channel/filtration,
crystallizer (water temperature/pressure/flow rate), casting
speed/traction, and surface quality of cast rod.
2. What is the regular maintenance cycle?
Daily: Clean the slag from the furnace mouth/flow channel; inspect
the burner, ignition system, and seals.
Weekly: verify thermocouples/temperature control instruments; clean
the scale in the water gap of the crystallizer; check the integrity
of the filter plate.
Monthly: Conduct a comprehensive inspection of the lining
thickness/cracks; calibrate the casting speed and traction
synchronization; replace aged sealing rings/gaskets.
Every year: overhaul the furnace body (repair/reline the furnace
lining); conduct a comprehensive inspection and maintenance of the
casting machinery and electronic control system.
3. Safety precautions?
High temperature protection: Wear high temperature resistant
clothing, protective face masks, and heat-insulating gloves to
avoid burns.
Explosion protection: Leakage is strictly prohibited in gas
furnaces, and regular leak detection is required; moist materials
are prohibited inside the furnace to prevent explosions caused by
water encountering aluminum liquid.
Emergency response: Equip with dry powder fire extinguishers and
dry sand.
4. The reason of the dimensions of the cast rods out of tolerance
(ellipsoidal, bent, uneven diameter)?
Reasons: deformation/wear of the crystallizer, uneven cooling
water, unstable casting speed, asynchronous traction machine,
uneven base.
Solution:
Crystallizer: Regularly inspect the roundness/wear of the inner
wall, and replace it promptly if it exceeds the tolerance; clean
the scale from the water gaps to ensure uniform cooling.
Speed / Traction: Stabilize the casting speed, calibrate the
synchronicity of the traction machine; ensure the base is level and
reduce vibration.
5. The reason of cast rod porosity / shrinkage cavity (internal
voids, poor density)?
Reasons: Excessively high pouring temperature, too fast casting
speed, insufficient cooling, poor shrinkage compensation, and a
wide solidification range of the alloy.
Solution:
Temperature / Speed: Reduce the pouring temperature, appropriately
decrease the casting speed, and extend the solidification time.
Cooling: Enhance the cooling intensity of the crystallizer to
ensure sufficient secondary cooling; optimize the water flow
distribution in the crystallizer.
Shrinkage compensation: Design the runner reasonably, strengthen
the riser for shrinkage compensation, and reduce shrinkage
cavities.
