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EN
The article presents an example of analysis of the influence of selected parameters deriving from data acquisition in foundries on the occurrence of Gas porosity defects (detected by Visual testing) in castings of ductile cast iron. The possibilities as well as related effectiveness of prediction of this kind of defects were assessed. The need to rationally limit the number of possible parameters affecting this kind of porosity was indicated. Authors also benefited from expert group's expertise in evaluating possible causes associated with the creation of the aforementioned defect. A ranking of these parameters was created and their impact on the occurrence of the defect was determined. The classic statistical tools were used. The possibility of unexpected links between parameters in case of uncritical use of these typical statistical tools was indicated. It was emphasized also that the acquisition realized in production conditions must be subject to a specific procedure ordering chronology and frequency of data measurements as well improving the casting quality control. Failure to meet these conditions will significantly affect the difficulties in implementing and correcting analysis results, from which INput/OUTput data is expected to be the basis for modelling for quality control.
EN
An innovative method for determining the structural zones in the large static steel ingots has been described. It is based on the mathematical interpretation of some functions obtained due to simulation of temperature field and thermal gradient field for solidifying massive ingot. The method is associated with the extrema of an analyzed function and with its points of inflection. Particularly, the CET transformation is predicted as a time-consuming transition from the columnar- into equiaxed structure. The equations dealing with heat transfer balance for the continuous casting are presented and used for the simulation of temperature field in the solidifying virtual static brass ingot. The developed method for the prediction of structural zones formation is applied to determine these zones in the solidifying brass static ingot. Some differences / similarities between structure formation during solidification of the steel static ingot and virtual brass static ingot are studied. The developed method allows to predict the following structural zones: fine columnar grains zone, (FC), columnar grains zone, (C), equiaxed grains zone, (E). The FCCT-transformation and CET-transformation are forecast as sharp transitions of the analyzed structures. Similarities between steel static ingot morphology and that predicted for the virtual brass static ingot are described.
EN
The Structural Peclet Number has been estimated experimentally by analyzing the morphology of the continuously cast brass ingots. It allowed to adapt a proper development of the Ivantsov’s series in order to formulate the Growth Law for the columnar structure formation in the brass ingots solidified in stationary condition. Simultaneously, the Thermal Peclet Number together with the Biot, Stefan, and Fourier Numbers is used in the model describing the heat transfer connected with the so-called contact layer (air gap between an ingot and crystallizer). It lead to define the shape and position of the s/l interface in the brass ingot subjected to the vertical continuous displacement within the crystallizer (in gravity). Particularly, a comparison of the shape of the simulated s/l interface at the axis of the continuously cast brass ingot with the real shape revealed at the ingot axis is delivered. Structural zones in the continuously cast brass ingot are revealed: FC – fine columnar grains, C – columnar grains, E – equiaxed grains, SC – single crystal situated axially.
EN
Preparation of moulding sand is a key process, determining the final quality of casting products. Special requirements are imposed at stabilising and optimising the parameters of the moulding sand so that it should maintain its properties required for moulding. These requirements can be satisfied as long as specialised mixing systems are used to prepare and control the sand mixing processes. The key elements of the system include sand mixers supported by dedicated measuring equipment operating in accordance with the approved control methods. Methods employed to determine the key properties of sand mix include the methods applied in on-line mixing control systems. The author’s research to date has led to the development of a method whereby the sand quality indicator is defined by a dynamic power demand signal from the mixer system. This study provides the selected measurement data, showing power consumption by the driving units in a prototype turbine mixer, used in laboratory conditions. The experimental programme utilises a state-of-the-art microprocessor system for measuring the parameters having relevance to power consumption by the mixer drive. Measurement signals of power demand by a paddle stirrer and a rotor are analysed. Testing was done for variable moisture content in moulding sands containing different kind of bentonite and for variable mixer pan loads. The methodology is supported by measurements of sand properties by conventional methods. The complete set of data and interrelations holding between them is utilised to describe the investigated processes in terms of dynamic systems, in accordance with the rules of automation. Attention is given to practical applications of the power measurement method in the analysis of mixing dynamics, in control of water-feeding system and in evaluation of energy demand for the process. The proposed methodology enables the comprehensive evaluation and selection of constructional parameters of devices of sand preparation systems.
PL
Istotnym procesem w technologii wykonania odlewów, decydującym o ich jakości, jest sporządzanie masy formierskiej. Szczególne wymagania dotycza stabilizacji i optymalizacji parametrów masy, określających jej właściwości i przydatność do wykonania form odlewniczych. Spełnienie tych wymagań zależy od zastosowanych systemów sporządzania i sterowania procesem mieszania składników masy oraz konstrukcji zastosowanych mieszarek. Podstawowym układem w systemie są mieszarki mas oraz współpracujące oprzyrządowanie pomiarowe, działające według określonych metod badawczych. Spośród metod służących do określania istotnych właściwości mas formierskich, wyróżnia się metody stosowane w układach sterowania on-line zasadniczym procesem mieszania mas. Na podstawie autorskich badań zdefiniowano metodę, w której miernikiem oceny jakości masy jest dynamiczny sygnał poboru mocy przez układy mieszające masę. W artykule przedstawiono wybrane wyniki pomiaru poboru mocy przez zespoły napędu prototypowej, laboratoryjnej mieszarki wirnikowej. W badaniach wykorzystano nowoczesny mikroprocesorowy system do pomiarów zbiorów parametrów charakteryzujacych pobór mocy przez napęd mieszarki. Przeprowadzono analizę uzyskanych sygnałów pomiaru mocy napędu mieszadła łopatkowego oraz wirnika. Badania wykonano przy zmianie stopnia nawilżenia mieszanych mas formierskich z bentonitem (różne gatunki) oraz przy zmiennym napełnieniu misy mieszarki. Dopełnieniem metodyki badawczej były pomiary właściwosci masy metodami klasycznymi. Pełny zbiór danych i ich wzajemnych zależności posłużył do opisu badanych procesów w ujęciu systemów dynamicznych zgodnie z regułami automatyki. Zwrócono uwagę na praktyczne mozliwości wykorzystania sygnału poboru mocy: w analizie dynamiki procesu mieszania, w sterowaniu procesem dozowania wody do masy formierskiej oraz w ocenie energochłonności procesu. Zaproponowana metodyka umożliwia takze kompleksowa ocene i dobór parametrów konstrukcyjnych urządzeń systemów sporzadzania masy.
EN
In this work an analytical solution is used to explain mechanism of carbon influence on the transition from graphite to cementite eutectic in cast iron. It is found that this transition can be related to (1) the nucleation potential of graphite (characterized directly by the cell count, N and indirectly by nucleation coefficients Ns and b) (2) the growth rate coefficient of graphite eutectic cell, [mi] (3) the temperature range, [delta]Tsc = Ts - Tc (where Ts and Tc is the equilibrium temperature of the graphite eutectic and formation temperature of the cementite eutectic respectively) and (4) the liquid volume fraction, fl after solidification of the pre-eutectic austenite. Method of estimation of Ns b and [mi] values was presented. It has been shown that the main impact of carbon on the transition from graphite to cementite eutectic consist in increasing the eutectic cell count and growth rate of graphite eutectic cell. Analytical equations were derived to describe the absolute, CT relative chilling tendency, CTr and chill, w of cast iron.
6
Content available remote Constrained/unconstrained solidification within the massive cast steel/iron ingots
EN
Some properties of the ingot and especially of the steel forging ingots depend on the ratio of a columnar structure area to an equiaxed structure area created during solidification. The CE transition is fundamental phenomenon that can be applied to characterize massive cast steel ingots produced by the casting house. The mentioned ratio is created spontaneously due to the rate of heat transfer towards the ceramic mould and then to the environment. The ceramic mould operates as an isolator. So that the thickness of the mould together with a growing solid fraction control the heat transfer and finally the ratio of the columnar structure area to the equiaxed structure area. At first the increase of heat accumulation within the ceramic mould is observed. Next the stationary state for heat transfer is created and finally a gentle abatement of the mould temperature associated with the heat output to the environment is expected. The steep thermal gradients correspond to the increase of heat accumulation in the ceramic mould. The steep thermal gradients are required to promote the columnar structure formation. The full heat accumulation in the mould corresponds well with the CE transformation while the appearance of the moderate thermal gradients is referred to the gentle temperature abatement within the ceramic mould. The equiaxed structure is expected within this period of heat transfer behavior. The steep thermal gradients involve the activity of viscosity gradient in the liquid. As the result a sedimentary cones are formed at the bottom of the ingot. The CE transformation is associated with competition between columnar and equaixed structure formation. At the end of competition a fully equiaxed structure is formed. The viscosity gradient is replaced by the thermophoresis which is the driving force for the deposition of some equiaxed grain layers onto the surface of C+E zone. The convection together with the gravity allow the layers to be uniform along the whole height of the ingot. Some equiaxed grain layers are also deposited at the bottom of ingot onto the surface of sedimentary cones due to activity of the gravity. Additionally, some macro-segregation effects are observed in the ingot [...]
7
Content available remote Analysis of power demand signal in laboratory rotary mixer
EN
The paper summarises the power measurement data for the main assemblies in a prototype turbine mixers for laboratory applications. Of particular interest are power demand signals in the paddle stirrer and the rotor. Tests were performed for the variable moisture content of the moulding sand containing bentonite. The process is described as dynamic and considered from the standpoint of automatics. Potential applications of the power demand signal are investigated in the context of the study of dynamics of the mixing processes, in terms of control of the water feeding to the moulding sand and for the purpose of evaluating the energy consumption.
8
Content available remote Some aspects of monitoring of foundry moulding sands preparation process
EN
The study outlines the basic features of a newly-designed computer-supported system for monitoring and recording the instantaneous power consumption, used to control the operating parameters of foundry mixers as well as moulding sand preparing process course. Basic idea of monitoring of power demand treated as the factor of quality evaluation of moulding sand preparation process have been described. The main coefficients and factors characterizing electric power demand by mixer drive are recalled. Comparison of values of the indicators of power consumption by various types of mixers has been done. The study has also summarized the preliminary test data of power consumption during moulding sand preparation process in a paddle mixer drive and roller mixer (Simpson type). Process parameters were varied during the tests: moisture content in moulding sand, load of the mixers pan and mixing time. Electric power demand is expressed by effective values, assuming the balanced load. As the mixing levels change, the technological parameters will change, too, and this fact might be utilized in monitoring of the mixing process. The power factor of the mixer drive cos would vary considerably during the mixer’s operation under loading. The selected results of tests performed to find the relationship between the technological and operational parameters and power consumption by a mixer drive have been presented. Two aspects of the monitoring system are considered to be of major importance: potential optimization of the mixing process in the function of energy consumption and control of the mixing process and its impacts on the properties and quality of thus prepared moulding sand. Potential following applications of the module for fast recording of instantaneous currents and voltages in a single or triple phase power supply system in other foundry machines and devices have been pointed out. Further research areas are indicated, to extend the system and the range of its using.
PL
Praca przedstawia w zarysie podstawową charakterystykę nowego, komputerowego systemu przeznaczonego do monitorowania i rejestracji chwilowego zapotrzebowania mocy, przeznaczonego do kontroli parametrów pracy mieszarek stosowanych w odlewnictwie jak również przebiegu procesu sporządzania masy formierskiej. Opisano podstawowa idee monitoringu poboru mocy przez mieszarkę traktowanego jako wskaźnik oceny jakości procesu sporządzania masy. Przedstawiono główne współczynniki i parametry charakteryzujace zapotrzebowanie mocy elektrycznej przez napęd mieszarki. Porównano wskaźniki charakteryzujące pobór mocy elektrycznej przez mieszarki różnych typów. Zaprezentowano także wyniki wstępnych badań poboru mocy przez mieszarkę łopatkową i krążnikową (typu Simpson). Badania prowadzono przy zmiennych parametrach, takich jak : wilgotność masy formierskiej, wielkość załadunku misy mieszarki oraz czas mieszania. Zapotrzebowanie mocy scharakteryzowano wartościami skutecznymi, uwzględniając załadunek mieszarki. Podczas procesu mieszania ulegają także zmianie parametry technologiczne, co może byc wykorzystane w kontroli procesu sporzadzania masy. Zaobserwowano istotna zmiane współczynnika mocy poboru mocy – cos, podczas pracy mieszarki przy zmiennym załadunku. Przedstawiono wybrane wyniki przeprowadzonych badan majacych na celu określenie zależności pomiędzy parametrami technologicznymi a parametrami pracy mieszarki oraz zapotrzebowaniem mocy. Podkreślono dwa podstawowe, ważne aspekty monitoringu poboru mocy: możliwość optymalizacji procesu mieszania z punktu widzenia jego energochłonnosci oraz kontrole procesu uwzgledniająca właściwości i jakość sporządzanej masy formierskiej. Wskazano możliwe, kolejne zastosowania szybkiej rejestracji chwilowych wartości natężenia i napięcia prądu w jedno i trójfazowych systemach zasilania maszyn i urządzeń odlewniczych. Zasygnalizowano obszary dalszych prac zmierzających do rozbudowy systemu i rozszerzenia jego zakresu zastosowania.
9
Content available remote The sort of carburization and the quality of obtained cast iron
EN
In the production of cast iron, the pig iron's amount in charge material is more and more often limited, and replaced by steel scrap. That extorts the necessity of know-how the carburization and one is looking for carburizers, which ensure obtaining big carbon increment as quickly as possible with the high repeatability and the ones which ensure getting the adequate quality of cast iron. The object of presented research was definition of the influence of charge materials' sort on the structure, course of solidification, and the effectiveness of process. The cast iron melts, which are presented below, are made only on the basis of steel scrap with portion of graphitoidal, coke and anthracite carburizers, which were added to the charge in solid. In the article one compared the carburizers in respect of their structure, chemical constitution and the effectiveness obtained during the carburization of liquid metal. The melting of cast iron, based on the special pig iron, was carried out as well. The course of melts, chemical constitution of obtained cast iron and its structure were presented. The comparison between quality distribution and the volume fraction of graphite in classes of size for the individual melts were achieved and the TDA curves were inserted.
EN
The paper addresses selected issues associated with the monitoring of the moulding sand preparation processes where the monitoring of power factors in the mixer drive is of primary importance. The study compares the indicators of electric power consumption by various types of mixers, summarizes the preliminary test data of power consumption in a paddle mixer drive. Process parameters were varied during the tests: moisture content and load. Coefficients and factors characterizing electric power demand are recalled. Two aspects of the monitoring system are considered to be of major importance: potential optimization of the mixing process in the function of energy consumption and control of the mixing process and its impacts on the properties of thus prepared moulding sand.
11
Content available remote Rationalization of foundry processes on the basis of simulation experiment
EN
The paper presents results of research obtained on the basis of simulation experiment, whose aim was to analyze the performance of cast iron foundry. A simulation model of automobile industry foundry was made. The course of the following processes was analyzed in a computer model: preparation of liquid cast iron, forming and filling the moulds, cooling and stamping the castings, cleaning and finishing treatment. The sheets of multi-criterion evaluation were prepared, where criteria and variants were assessed by means of subjective point evaluation and fuzzy character evaluation. The paper presents an analysis example of finishing activities of castings realized in foundry on traditional machines and efficient presses and in cooperation. On the basis of reports from a simulation experiment information was achieved related to activities' duration, load of accessible resources, the problems of storage and transport, bottle necks in the system and appearing queues in from of workplaces. The research used a universal modelling and simulation packet for production systems - ARENA
EN
In the paper, main assumptions, algorithms and functions of author’s KMES Quality system are discussed. Its working version is tested in chosen foundry by near 2 years. This system is applied to enlarge the use of chosen technological data accessible during foundry processes. The data can be introduced by means of keyboard directly in the fields (windows) present on the PC screen according to program commands, instead of report-manuscripts containing measured results, or from the automated measurement recording system by direct data import to KMES Quality system. In the paper, a way of technological data acquisition with their further integration into main foundry databases and their processing, with taking into consideration e.g. kind of casting assortment, current time, sequences of measurements, are presented. Also the capabilities of linking KMES Quality system with SAP R/3 system existing in this foundry useful to quality assurance is show.
13
Content available remote The rate and effectiveness of carburization to the sort of carburizer
EN
The obtaining of demanded carbon contents during melting the cast iron with bounded pig iron's portion is important problem for many foundries. There are searched the effective methods and carburizers, which would ensure obtaining of big carbon increases with great repeatability as quick as possible. The aim of presented researches was definition of influence of essential factors characterized the carburization and the sort of carburizer on the rate and effectiveness of process. The cast iron melts are presented only on the basis of steel scrap with the portion of graphitoidal, coke and anthracite carburizers. Two methods of carburization are taken into consideration during the experiments were carried out: the addition of carburizer to charge in solid in the initial period of melting and addition of carburizer on surface of liquid metal. The obtained researches results and their analyze allow to choose the corresponding method and the sort of carburizer. One can state, that the best carburizer is synthetic graphite, if the rate and effectiveness of process is considerate and the best method of carburization in the electric inductive furnace is addition of carburizer to charge in solid. In the subsequent part of researches the analyze of influence of carburizer on the structure of grey cast iron and ductile cast iron. The initial researches has showed the differences in obtained structures of synthetic cast iron melted only on the basis of steel scrap and defined kind of carburizer.
14
Content available remote Crystallization analysis of AlSi7Mg (AK 7) alloy with use of "ATND" method
EN
The paper presents results of non-ferrous metal crystallization research with use of ATND method. The research was carried out in the Faculty of Chipless Forming Technology, University of Bielsko-Biała. The new method of analysis of non-ferrous metals alloy crystallization assures complete picture of generated structural components of the alloy. Structural components defined in the tested alloy using ATND method have been verified by X-ray microanalysis, which unambiguously has confirmed their presence. Below are presented results of the crystallization analysis with ATND method in graphic form (crystallization diagrams). In crystallization diagrams of AK7 alloy there were shown curves (thermal curve with its derivative, voltage curve and its derivative). Individual structural components crystallizing in the tested alloy are reflected on curves of the method in form of characteristic peaks. The research was carried out on AK7 aluminum cast alloy. Moreover, the paper shows the structures of the tested alloy together with marked structural components, identified with use of X-ray microanalysis.
15
Content available remote A characteristic of design solutions for flask moulding lines
EN
Moulding machines used in manufacture of moulds from synthetic bentonite sands constitute basic equipment of mechanised stands, work centres, and production lines. In the present article, a short characteristic of this equipment was given, basing on the generally accepted criteria of classification taking into consideration novel design solutions and principles of cooperation between individual sub-assemblies. Moulding equipment offered by domestic producers was described with emphasis put on models representative of the distinguished classes and groups.
16
Content available remote Inverse problems in the thermal theory of foundry processes
EN
In the paper the applications of inverse problems in the thermal theory of foundry processes are discussed. Both the macro models of solidification (in particular the fixed domain approach) and macro/micro ones are considered. The information necessary in order to determine the unknown parameters of the process results from the knowledge of cooling (heating) curves at the selected set of points from casting and/or mould subdomains. The identified values can correspond to the thermophysical parameters of casting and mould, parameters appearing in boundary conditions and initial temperatures. In the paper the newest results obtained in this scope by the authors are presented. The examples of numerical solutions are also shown.
17
Content available remote Wykorzystanie energii mikrofalowej w procesach odlewniczych
PL
Przedstawiono możliwości zastosowania energii mikrofalowej do określania wilgotności materiałów sypkich, do suszenia rdzeni pokrytych wodnymi powłokami ochronnymi, do suszenia i utwardzania mas formierskich i rdzeniowych z lepiszczami bentonitowymi oraz utwardzania rdzeni z żywicami termo- i chemoutwardzalnymi. Omówiono ponadto wyniki badań nad zastosowaniem nagrzewania mikrofalowego w procesach utylizacji odpadów przemysłowych oraz wytwarzania kompozytów.
EN
The paper presents possibilities of using microvaves to dry cores covered with aqueous protective coatings, to dry and harden moulding and core sands with bentonite binders and to determine moulding sand humidity with the gravimetric method. A possibility to harden cores containing thermohardening and chemically hardening resins is also presented. Microwave energy used to syntheses composite components allows reduce processing times and save energy and simultaneously engage selective heating of components having different dielectric properties.
18
Content available remote Identification of internal heat source capacity in the heterogeneous domain
EN
The heterogeneous domain Ωbeing the composition of two domains (Ω1, Ω2) is considered. It is assumed that in the first domain Ω1 the internal volumetric heat sources act. On the basis of knowledge of heating (cooling) curves at the selected set of Ω2 the capacity of internal heat sources in Ω1 is identified. The inverse problem formulated in this way is interesting from the practical point of view. For example, a such situation takes place during the casting solidification. The evolution of latent heat in the casting domain causes that in Ω1 the internal heat sources appear, while in the mould domain this component of energy equation is equal to 0. Additionally the measurements of temperature in the mould are essentially simpler from the technical view-point. In the paper the theoretical base of the problem and the examples of numerical realization are discussed.
19
Content available remote Wybrane zastosowania optymalizacji rozmytej w sterowaniu procesami odlewniczymi
PL
W artykule przedstawiono ogólny model matematyczny optymalizacji rozmytej oraz klasyfikację metod programowania matematycznego, które można wykorzystać w rozwiązywaniu zadań optymalizacji rozmytej. Przedstawiono także wybrane modele rozmytości parametrów dowolnego procesu technologicznego. Artykuł uzupełniono przykładami odlewniczych zastosowań optymalizacji rozmytej.
EN
The article presents a mathematical model of fuzzy optimization and a classification of the mathematical programming methods which can be used to solve the fuzzy optimization problems. The author has described selected fuzzy models of the technological processes parameters. The examples of the fuzzy optimization in foundry calculations have been included.
20
Content available remote Charakterystyka i zastosowania algorytmów optymalizacji rozmytej
PL
W artykule przedstawiono skróconą charakterystykę algorytmów optymalizacji rozmytej, które można wykorzystać do realizacji obliczeń parametrów technologicznych w procesach produkcyjnych odlewni. Przedstawiono wyniki przykładowych obliczeń wykonanych z zastosowaniem algorytmów optymalizacji rozmytej. W artykule podano możliwości praktycznych odlewniczych zastosowań algorytmów optymalizacji rozmytej.
EN
The paper presents a short characteristic of the fuzzy optimization algorithms, which can be used in technological parameters calculations for foundry processes. The examples of the calculations results, realized with the fuzzy optimization algorithms have been included. Various possibilities of the practical usage the optimization algorithms have been presented.
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