When it comes to the induction furnace charge calculation, we have to compare the induction furnace with the cupola. Compared with the cupola, melting molten iron with an induction furnace can not only reduce environmental pollution, but also facilitate the control of molten iron quality, with less investment, and also facilitate the production of various cast iron grades of nodular cast iron, vermicular cast iron and gray cast iron. The production mode is very flexible. Compared with melting with pig iron as the main ingredient, melting molten iron with a scrap carburization process can reduce the cost of molten iron by 1000 yuan. The medium-frequency electric furnace can realize self-diagnosis and protection, reduce maintenance time and workload, and can be connected with the automatic control and management system of the computer melting process. It is easy to operate and manage. Therefore, after the 1990s, most of the new cast iron foundries abroad and in China use coreless medium-frequency induction furnaces to melt molten iron.
When the induction furnace is used to melt molten iron, the quality of molten iron can be significantly improved and the energy consumption per ton of molten iron can be reduced by melting the molten iron with the clean return material after crushing and shot blasting. The foundry has conducted production tests on a 10-ton medium-frequency furnace. It uses clean recycled materials to produce a high-power diesel engine cylinder head, and the induction furnace charge calculation is that the reject rate of casting eyelets is reduced by 6 percentage points, reducing the power consumption of molten iron melting by 90kW • h/t; At the same time, melting molten iron with clean furnace charge can effectively reduce the labor intensity of workers' slagging, improve the casting and melting operation environment, reduce the slagging phenomenon at the furnace mouth of the power frequency furnace, solve the difficult problem after slagging at the furnace mouth, improve the service life of the furnace lining of the power frequency furnace by 20%, and improve the melting production efficiency. Therefore, when using the medium frequency induction furnace to melt molten iron, great attention should be paid to the purification of the melted furnace charge, especially the crushing of the return charge The problem of shot blasting purification is a very important link in bringing into play the benefits of melting molten iron in medium frequency furnace.
Melting molten iron in an induction furnace can also produce gray cast iron cylinder heads with excellent processing performance. For many years, there has been a debate about the influence of melting furnace type on the machinability of gray cast iron, that is, most founders believe that the gray cast iron produced by induction furnace melting is less machinability than that produced by cupola melting. In 1998, the American Foundry Association organized researchers to study the effect of induction furnace melting and cupola melting on the machinability of gray cast iron (equivalent to HT150, HT200, HT250) by turning test and drilling test. The research showed that the machinability of materials during cupola melting is not better than that of induction furnace melting, and for some machinability data, the machinability of gray cast iron during induction furnace melting is better.
We also studied the problem that the gray castings produced by induction furnace melting are less machinable than those produced by cupola melting, and verified in mass production of HT250 cylinder block: the machinability of cylinder block produced by medium frequency induction furnace is 20% higher than that produced by hot blast cupola and electric furnace double melting, and the mechanical properties of castings are improved by 10%, the metallographic structure is improved, and the compactness of cylinder block castings is improved, This shows that melting molten iron in the medium frequency induction furnace can also produce gray cast iron cylinder heads with excellent processing performance. The key is to adopt a good melting process - using a scrap steel carburizing process, using a high-quality carburizing agent and a good inoculation process.
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