Magnesium Alloy Melting Furnace Structure Design And Research Based On Flow Heat Transfer Analysis

The development of magnesium (mg) alloy products manufacturing industry has caused a wide attention from research institutes and industries on mg alloy melting furnace die casting machine and recycling facility, the key equipments in mg alloy product manufacture. However, due to some particular characteristics of mg alloy, e.g. highly flammable, high die-casting temperature, small thermal capacity etc. it is more difficult to design or produce these facilities, thus only several developed countries have this ability. There are some domestic companies producing mg alloy furnaces though, the performance on energy economy, quantity pouring precision, temperature control precision and melting quality is far behind. Based on this background, the Science and Technology Department of Zhejiang Province's project, Research and Development of The Eco-friendly Mg Alloy Remelting Technique & Quantitative Pouring Furnace, was proposed.This thesis has designed and researched the structure of mg alloy melting furnace. First, the furnace structure was designed. Then, it was optimized based on mg melt flow simulation, aluminum melting experiments and redesigned the magnesium alloy melting furnace. Factors that affect the pouring chamber temperature were analyzed as well.Base on orthogonal test method, the finite-elements analysis and simulation on mg alloy melt flow during the continuous pouring procedure were conducted, the results processed by range analysis method indicates that when the volume ratio of pouring chamber and melting chamber is 1 to 3, temperature fluctuation in pouring chamber reaches the minimum value. Based on this results, aluminum melting experiments were proceeded next, which showed that distance between heating wire and crucible, ingot weight, pouring frequency and ingot pre-heat temperature affect the fluctuation in sequence. The proper distance to minimize the fluctuation and energy consumption is 50mm. Also, an optimized melting scheme was concluded through analyzing the diagrams of influential factors resulted from the simulation results, and the scheme was validated through aluminum melting experiments.The magnesium alloy melting furnace was redesigned according to optimal structure from mg alloy melt flow simulation and aluminum melting experiments. The experiments results indicated the furnace developed and designed through methods mentioned above meet the energy economy requirements.