Casting Machine Maintenance Work Instructions
1. Purpose
To clarify production equipment usage and maintenance requirements, carry out effective and planned preventive maintenance on the casting machine, and ensure the equipment continuously meets the requirements for achieving product conformity.
2. Scope of Application
These work instructions apply to the use, maintenance, and management of casting machines used in melting and casting plants, including direct-chill (DC) casting machines.
3. Equipment Composition
The direct-chill casting machine consists of the following components:
- Refractory-lined launder (flow trough)
- Graphite ring mold / crystallizer
- Water tank assembly
- Piston mechanism for drawing solidified metal from the crystallizer
- Internally-guided double-acting hydraulic cylinder driven by a dedicated hydraulic power unit
The equipment produces slabs and round billets of various specifications, with a maximum casting length of 7.9 meters.
4. Key Equipment Parameters
- Casting alloy types: 2xxx, 5xxx, 6xxx, 7xxx series aluminum alloy
- Maximum casting length: 7900mm
- Various billet diameters supported
5. Routine Maintenance Requirements
5.1 Daily Inspections
- Check the condition of furnace heating during temperature ramp-up
- Inspect dehumidification fans and water pump operation
- Verify hydraulic system pressure and fluid levels
- Check for oil leaks around hydraulic cylinders and connections
- Inspect cooling water flow and temperature
5.2 Periodic Inspections
- Inspect cooling fans on all frequency converters
- Check AC contactor engagement sounds in control cabinets
- Verify graphite ring mold condition and replace when worn
- Inspect refractory lining of the launder for cracks or erosion
- Check all electrical connections for tightness
5.3 Preventive Maintenance Schedule
- Clean equipment thoroughly after each production run
- Tighten loose fasteners and connections weekly
- Replace lubricating oil and hydraulic fluid per manufacturer schedule
- Inspect and calibrate sensors and gauges monthly
- Perform comprehensive annual overhaul including hydraulic system flush
6. Safety Precautions During Maintenance
- Always lock out and tag out the machine before performing maintenance
- Ensure all power sources are disconnected
- Use appropriate lifting equipment for heavy components
- Wear proper PPE including heat-resistant gloves and safety glasses
- Never work under suspended loads
