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EN
The paper presents the results of investigations concerning the influence of negative (relative) pressure in the die cavity of high pressure die casting machine on the porosity of castings made of AlSi9Cu3 alloy. Examinations were carried out for the VertaCast cold chamber vertical pressure die casting machine equipped with a vacuum system. Experiments were performed for three values of the applied gauge pressure: -0.3 bar, -0.5 bar, and -0.7 bar, at constant values of other technological parameters, selected during the formerly carried initial experiments. Porosity of castings was assessed on the basis of microstructure observation and the density measurements performed by the method of hydrostatic weighing. The performed investigation allowed to find out that – for the examined pressure range – the porosity of castings decreases linearly with an increase in the absolute value of negative pressure applied to the die cavity. The negative pressure value of -0.7 bar allows to produce castings exhibiting porosity value less than 1%. Large blowholes arisen probably by occlusion of gaseous phase during the injection of metal into the die cavity, were found in castings produced at the negative pressure value of -0.3 bar. These blowholes are placed mostly in regions of local thermal centres and often accompanied by the discontinuities in the form of interdendritic shrinkage micro-porosity. It was concluded that the high quality AlSi9Cu3 alloy castings able to work in elevated temperatures can be achieved for the absolute value of the negative pressure applied to the die cavity greater than 0.5 bar at the applied set of other parameters of pressure die casting machine work.
EN
Vacuum conditions in foundry installations are generated using electric-driven vacuum pumps. The purpose of the experiment is to evaluate the performance of a vacuum-assisted system for compaction of moulding sand basing on registered plots of selected electric power parameters of the power-supplying system of the pumps. Model testing done on an experimental vacuum system installation, power-supplied from a system incorporating the recorders of instantaneous current and voltage values. Following the numerical procedure, the experimental data are analysed to yield mathematical relationships between the variations of the generated vacuum pressure levels and variations of selected electric power parameters. Registered and computed values of selected parameters: instantaneous and RMS voltage and current values, active, reactive and apparent power levels and power coefficient allow for diagnosing the adequacy and reliability of the system operation. According to the authors, the applied monitoring of the power parameters of a vacuum-assisted installation may become an effective and easy practical method of evaluating the performance of such installations, used also in foundry plants.
EN
In this article the main problems related with the proper choice of the design and operation parameters of vacuum installation in vacuum moulding system have been discussed. In such system a vacuum are generated using electric-driven vacuum pumps. The aim of the experiment is to evaluate the performance of a vacuum system basing on registered plots of selected electric power parameters of the power-supplying system of the pumps with parallel measurements instantaneous values of pressure in selected points of model stand. The measurements system for power-supply unit has incorporated the recorders of instantaneous current and voltage values. Following the suitable numerical procedure, the experimental data are analysed to yield mathematical relationships between the variations of the generated vacuum pressure levels and variations of selected electric power parameters. According to the authors, the applied measurements system of the parameters of a vacuum-assisted installation may become an effective and easy practical method of evaluating the performance of such installations, used also in industry.
4
Content available remote Evaluation of automatic vacuum- assisted compaction solutions
EN
Currently on the mould-making machines market the companies like: DiSA, KUENKEL WAGNER, HAFLINGER, HEINRICH WAGNER SINTO, HUNTER, SAVELLI AND TECHNICAL play significant role. These companies are the manufacturers of various solutions in machines and instalations applied in foundry engineering. Automatic foundry machines for compaction of green sand have the major role in mechanisation and automation processes of making the mould. The concept of operation of automatic machines is based on the static and dynamic methods of compacting the green sand. The method which gains the importance is the compacting method by using the energy of the air pressure. It's the initial stage or the supporting process of compacting the green sand. However in the automatic mould making machines using this method it's essential to use the additional compaction of the mass in order to receive the final parameters of the form. In the constructional solutions of the machines there is the additional division which concerns the method of putting the sand into the mould box . This division distinquishes the transport of the sand with simultaneous compaction or the putting of the sand without the pre-compaction. As the solutions of the major manufacturers are often the subject for application in various foundries, the authors of the paper would like/have the confidence to present their own evaluation process confirmed by their own researches and independent analysis of the producers' solutions.
5
Content available remote Analysis of Basic Phenomena Occurring in the Vacuum-Assisted Moulding Process
EN
Variant of vacuum-assisted moulding process, proposed by the authors, can be used (as the initial stage of moulding) either in new moulding machines or during modernization of existing moulding machines as well. In the article analysis of basic phenomena in the vacuum-assisted moulding process was based on: high speed imaging technique, dynamic air pressure measurements in the working space of the prototype moulding machine, as well as typical compaction effect measurements. The exemplary results of the simulation of the air flow process in the working space of the moulding machine prototype, can be useful in making the proper choice of basic machine parameters.
PL
Proces formowania podciśnieniowego, w wariancie zaproponowanym przez autorów, może być wykorzystany jako wstępny etap zagęszczania, w nowych maszynach formierskich, jak również przy modernizacji użytkowanych maszyn. W artykule przedstawiono analizę podstawowych zjawisk zachodzących podczas formowania podciśnieniowego. Analizę oparto o wyniki badań procesu formowania podciśnieniowego wykorzystujące: technikę szybkiego filmowania, dynamiczne pomiary ciśnienia w przestrzeniach roboczych prototypowej formierki oraz o typowe pomiary efektów zagęszczania. Przedstawiono przykładowe wyniki symulacji procesu przepływu powietrza w przestrzeniach formierki podciśnieniowej, przydatne w doborze podstawowych parametrów maszyny.
6
Content available remote Podstawowe parametry procesu formowania podciśnieniowego
PL
W artykule przedstawiono analizę odmian maszyn formierskich, w których zastosowano instalacje podciśnieniowe. Na podstawie wyników własnych badań procesu podciśnieniowego przedyskutowano najważniejsze parametry wpływające na przebieg procesu i uzyskiwane efekty zagęszczania. W badaniach zastosowano metodę szybkiego filmowania procesu oraz dynamiczne pomiary ciśnienia.
EN
In the article variation of vacuum assisted moulding machines design has been presented. On the base of own research of vacuum assisted moulding results the basic parameters influenced on the process and obtained compaction effects have been discussed. In the investigation tests the high-speed-imaging method and dynamical pressure measurement have been used.
7
Content available remote Badanie wybranych aspektów procesu formowania podciśnieniowego
PL
W maszynowym wykonywaniu form odlewniczych dominuje obecnie zagęszczanie dwustopniowe z wykorzystaniem doprasowania w ostatniej fazie formowania. W artykule przedstawiono analizę formowania podciśnieniowego z doprasowaniem oraz wybrane wyniki badań tej metody formowania. Opisano również występujące warianty formowania podciśnieniowego jako wstępnego etapu zagęszczenia masy. Określenie charakterystyki procesu formowania pozwoli na dobór optymalnych parametrów pracy maszyny.
EN
In current moulding machines, two-phase compaction process is usually used. The squeezing is a final operation. In the article the analysis of vacuum moulding process as well as selected results of research of vacuum and squeezing moulding have been presented. The possible variation of vacuum moulding used as initial compaction of the mould have been also described. The evaluation of the such processes characteristics is helpful in choice of proper operation parameters of moulding machine.
8
Content available remote Analiza wybranych aspektów formowania podciśnieniowego
PL
Oferta maszyn formierskich jest bardzo szeroka. Realizowane jest zwykle zagęszczanie wieloetapowe z wykorzystaniem doprasowania w ostatniej fazie formowania. Nowoczesne formierki umożliwiają zmianę parametrów pracy maszyny. Dobór optymalnych parametrów wymaga znajomości realizowanego procesu zagęszczania. W pracy przedstawiono warianty formowania podciśnieniowego z doprasowaniem oraz wybrane wyniki badan tej metody.
EN
Current offer of moulding machines are very wide. There are usually used two-step compaction process. The final compaction method is squeezing. Modern moulding machines give possibilities of operation parameters changing. The proper choice of operation parameters need serious knowledge about realised compaction process. In the paper the own research results and analysis of moulding method based on suction pre-compaction and squeezing. The selected moulding machines using this method of compactions have been described.
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