Optimization of continuous casting process in steel manufacturing industry Muhammad Iqbal Hussain School of Manufacturing Engineering. Universiti Malaysia,Perlis Kangar Perlis Malaysia [email protected]Zuraidah Mohd Zain School of Manufacturing Engineering. Universiti Malaysia,Perlis Kangar Perlis Malaysia [email protected]NG. Hooi. Xian School of Manufacturing Engineering. Universiti Malaysia,Perlis Kangar Perlis Malaysia [email protected]Abstract— The continuous casting process is used for solidifying molten steel into semi-finished steel. The technology for Secondary Cooling Zone (SCZ) is extremely important for output of casting machine and billet quality. Occurrences of internal defects e.g. edge cracks commonly known as diagonal cracks in the continuous cast product of steel Grade H is commonly related to the uniformity of the water flow rate control in SCZ. Design of Experiment, DOE is used in analyzing the parameters that influences the quality of the billet production; Secondary Zone 1 st sector water flow rate, Secondary Zone 2 nd sector water flow rate and Secondary Zone 3 rd sector water flow rate. The optimum results are attained to achieve the best combination of parameters value to be used in continuous casting process. Keywords: diagonal cracks, DOE, secondary zone 1 st sector water flow rate, secondary zone 2 nd sector water flow rate, secondary zone 3 rd sector water flow rate. 1. Introduction Billet is a semi-finished steel product produced out from different types of scrap metals for the used in construction site as well as to fulfil needs in other secondary processes, e.g. rolling or forging into finished product, e.g. round bar, deformed bar or wire rod in coil forms. Today in the modernized world, the demand for billets continues to rise. Hence there is a growing need to understand the causes of defects occurring in the continuous casting process to improve casting conditions for production of high quality billets, thus increasing yield production, reducing wastages and energy consumption in return for higher profit to the company [1]. The research improvement concentrates on the finding out the causes of diagonal cracks which commonly occurs during the casting process in the Continuous Casting Machine (CCM). The casting process is the most important and critical process whereby the molten steel will be cast out through a copper mould while passing through a series of cooling sections to maintain the shape and size of the billets. The crack of the continuous casting billet is a fatal defect which may be cause by various different reasons. In this study, series of experiments are carried out with the aid of Design Expert, Design of Experiment (DOE) software to determine the processing parameters in reducing and avoiding the formation of such cracks. 1.2. Problem Statement Diagonal cracks are defects which are regularly occurring through strands the 6-strand after being cast out from the casting machines. The occurrence of such defect tends to lower the yield production thus leading to loss in profit and material wastage. The presumed parameters influencing such Scientific Cooperations International Workshops on Engineering Branches 8-9 August 2014, Koc University, ISTANBUL/TURKEY 305
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Optimization of continuous casting process in steel manufacturing industryeng-scoop.org/papers2014/IWME/7.M.Iqbal.pdf · · 2014-09-03Optimization of continuous casting process
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Optimization of continuous casting process in steel