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Mulling and its Effect on the Properties of Sand-Water-Bentonite Moulding Mixture

Gawronová Martina, Kielar Š., Lichý Petr

Archives of Foundry Engineering

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2022

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Vol. 22, iss. 3

107--112

EN

Today, foundries are facing increasing demands for greener and more economical production while maintaining or improving the quality of the castings produced. The importance and use of green sand mixtures using bentonite as a binder are thus coming to the fore once again. They have the advantage of both eliminating the chemicalization of production and also allowing the immediate use of the already used mixture, including the binder, after adjustment of the composition and mulling. In order to maintain the quality of the resulting castings, it is necessary to monitor the properties of the moulding mixture through a series of laboratory tests. It is also essential to look at the processing quality of these mixtures, i.e. the combination of good mulling quality and efficient mulling time, which is often neglected. It is the quality of mulling and the effective mulling time that help to develop the bonding properties of the bentonite, improve the properties of the mixture, determine the efficiency of the muller and possibly reduce the time and energy required for mulling. The aim of this work is to present the effect of mulling on the properties of sand-water-bentonite mixtures. The properties studied are mainly the compactability, strength characteristics, moisture content of the mixture and the order of addition of raw materials.

2

Sytuacja polskiej branży odlewniczej w 2020 roku

Liszka Katarzyna, Dobosz Witold

Przegląd Odlewnictwa

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2021

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Vol. 71, nr 7-8

394--398

PL

Artykuł przygotowany został w oparciu o badanie ankietowe przeprowadzone wśród polskich odlewni. Na podstawie zebranych danych przedstawiono stan polskiego odlewnictwa w 2020 roku i wpływ pandemii COVID-19 na poziom produkcji krajowej oraz wskaźniki pośrednie jak poziom zatrudnienia, czy wielkość eksportu. Tłem do prezentowanych wyników jest rok 2019 i ogólna sytuacja w światowym i europejskim przemyśle odlewniczym. Przygotowane opracowanie stanowi bazę wiedzy dla przedstawicieli polskiego odlewnictwa w rozmowach z władzami gospodarczymi i organizacjami pozarządowymi oraz ważne na-rzędzie dla promocji i budowania konkurencyjności na arenie międzynarodowej, zwłaszcza w kontaktach z organizacjami międzynarodowymi takimi jak World Foundry Organization i CAEF – The European Foundry Association.

EN

The article was prepared on the basis of a survey conducted among Polish foundries. It presents the state of the Polish foundry industry in 2020 and the impact of the COVID-19 pandemic on the level of domestic production as well as indirect factors such as the level of employment or the volume of exports. The background for the analyzed results is data from 2019 and the general situation in the global and European foundry industry. The prepared study can become a base for representatives of the Polish foundry industry in their encounters with economic authorities and non-governmental organizations, and an important tool for promoting and building competitiveness on the international arena, especially in contacts with international organizations such as the World Foundry Organization and CAEF –The European Foundry Association.

3

Comparison of Molding Sand Technology Between Alphaset (APNB) and Furan (FNB)

Ghosh Dipak K.

Archives of Foundry Engineering

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2019

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iss. 4

11--20

EN

The paper focuses on investigation of properties of two most widely used self-set sand binder systems APNB and FNB across the Globe, for making molds and cores in foundries to produce castings of different sizes involving wide range of metals and alloys, ferrous and nonferrous. This includes study of compression strength values of samples made out of molding sand at different binder addition level using new, mechanically reclaimed (MR) and thermally reclaimed (TR) sand. Strength values studied include dry strength (at room temperature) at specified intervals simulating different stages of mold handling, namely stripping and pre heating, followed by degraded strength after application of thinner based zircon wash by brush, subsequent lighting of, then checking strength both in warm (degraded strength) & cold (recovered strength) conditions. Throughout the cycle of mold movement from stripping to knock out, strength requirements can be divided into two broad classifications, one from stripping to closing (dry strength) and another from pouring to knock out (hot & retained strength). Although the process for checking of dry strength are well documented, no method using simple equipments for checking hot & retained strength are documented in literature. Attempts have been made in this paper to use some simple methods to standardize process for checking high strength properties using ordinary laboratory equipments. Temperature of 450°C has been chosen by trial & error method to study high temperature properties to get consistent & amplified values. Volume of gases generated for both binders in laboratory at 850°C have also been measured. Nature of gases including harmful BTEX and PAH generated on pyrolysis of FNB and APNB bonded sands are already documented in a publication [1]. This exercise has once again been repeated in same laboratory, AGH University, Poland with latest binder formulations in use in two foundries in India.

4

Energy Savings in Foundries through Yield Improvement and Defect Reduction in Castings

Chokkalingam B., Raja V., Dhineshkumar M., Priya M., Immanual R.

Archives of Foundry Engineering

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2018

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Vol. 18, iss. 1

15--18

EN

Energy conservation is an important step to overcome the energy crisis and prevent environmental pollution. Casting industry is a major consumer of energy among all the industries. The distribution of electrical energy consumed in all the departments of the foundry is presented. Nearly 70% of the energy is consumed especially in the melting department alone. Production of casting involves number of process variables. Even though lot of efforts has been taken to prevent defects, it occurs in the casting due to variables present in the process. This paper focuses the energy saving by improving the casting yield and by reducing the rejections. Furthermore an analysis is made on power consumption for melting in the induction furnace to produce defective castings and improvement in the casting yield. The energy consumed to produce defective castings in all other departments is also presented. This analysis reveals that without any further investment in the foundry, it is possible to save 3248.15 kWh of energy by reducing the rejections as well as by improving the casting yield. The redesign of the feeding system and the reduced major rejection shrinkage in the body casting improved the casting yield from 56% to 72% and also the effective yield from 12.89% to 66.80%.

5

Zasady projektowania struktury technologicznej gniazd formowania maszynowego wyposażonych w przenośniki wałkowe

Wrona R., Stawowy A., Macioł A.

Archiwum Odlewnictwa

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2005

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R. 5, nr 17

375--384

PL

Gniazda formowania maszynowego wyposażone w przenośniki wałkowe są bardzo rozpowszechnione w odlewniach o produkcji mało seryjnej i przy zróżnicowanym asortymencie odlewów. Szczególnie mają zastosowanie w systemie okresowego zalewania form, w którym konieczne jest magazynowanie form przed zalaniem na tzw. powierzchniach odstawczych utworzonych z ciągów przenośników wałkowych. Strukturę gniazd tworzą pary maszyn wraz z urządzeniami transportu poziomego i pionowego. Główne zadania, które rozwiązano w opracowaniu dotyczą określenia powierzchni pola odstawczego oraz organizacji całego procesu od momentu wykonania formy do jej wybicia ze skrzynek. Procedura rozwiązania ujmuje postępowanie optymalizacyjne.

EN

The work centers of the machine moulding equipped with the roller conveyers are very popular in the foundries with short-run production and with a different assortment of castings. They are used especially in a system of a periodic pouring into moulds where it is necessary to store the moulds before pouring on the so called deposit surfaces formed by the sequence of the roller conveyers. The structure of the work centers is formed by the pairs of the moulding machines together with facilities of the horizontal and vertical handling. The main tasks which solutions are presented in this study refer to the designation of the surface of the deposit area and to the organization of the whole process from the moment when the mould is maid to its extraction from the flask. The procedure of the solution formulates the most favourable conduct.

6

Nowoczesne koncepcje planowania produkcji w systemach klasy ERP

Duda J., Stawowy A.

Archiwum Odlewnictwa

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2005

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R. 5, nr 17

75--82

PL

W pracy przedstawiono najnowsze koncepcje, które są implementowane we współczesnych systemach zintegrowanego zarządzania przedsiębiorstwem klasy ERP. Przeanalizowane zostało podejście do potwierdzania zamówień w systemach typu Available to Promise oraz Capable to Promise. Omówiono także planowanie i sterowanie produkcją z wykorzystaniem nowoczesnych systemów zaawansowanego planowania i harmonogramowania (APS). Podejścia te zilustrowane zostały przykładami wdrożeń systemów klasy ERP oraz APS w zakładach odlewniczych.

EN

Modern conceptions implemented in contemporary ERP type systems have been presented in the paper. An approach to order promising in systems of Available to Promise and Capable to Promise has been analyzed. The production planning and control with the use of modern Advanced Planning and Scheduling Systems has been also characterized. Presented approaches has been illustrated with the examples of EPR and APS systems implementations in some iron foundries.