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1

The determination of the thickness of the composite layers

Baron C., Bartocha D., Szajnar J.

Archives of Computational Materials Science and Surface Engineering

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2009

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Vol. 1, nr 3

139-147

EN

Purpose: In this article, the results of thermal simulation of composite layer formation on the steel model casting are shown. The main aim of researches was to work out the technological parameters of composite layer formation process, for which it is possible to get good quality reinforcement layer with desirable thickness. Design/methodology/approach: Both the distribution of temperature in model casting and the course of temperature changes in characteristic points of composite premould, were determined for assumed changes of the chosen technological parameters. The numerical calculations were conducted with the use of software NovaFlow&Solid 2.9 r81. Findings: Both the good quality and the desirable thickness of the composite layer depend on the parameters of process and the pouring temperature during the casting process. Research limitations/implications: Researches made possible to determine technological parameters, which have an direct effect on this process, and the criterions, which should be taken by casting technology of this kind of casting. Practical implications: Thanks to obtained results, it is possible to work out the guidelines and rules for projecting the construction and the selection of technological parameters of casting with the surface composite layer. Originality/value: The obtained results and the analysis of them allow to determine the basic guidelines for designing technology and construction of casting with the composite layer.

2

Program do obliczania grubości powierzchniowych warstw kompozytowych na odlewach staliwnych

Baron Cz., Szajnar J.

Kompozyty

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2008

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R. 8, nr 1

15-21

PL

Proces tworzenia się kompozytowych warstw powierzchniowych jest złożony i zależy od wielu czynników technologicznych i materiałowych. Stąd też nie można jednoznacznie określić, jaka będzie jej grubość w danym miejscu odlewu. Skłania to do poszukiwania grubości warstwy kompozytowej jako pewnej zmiennej losowej. W pracy przyjęto założenie, aby poszukiwaną zmienną losową modelować prostym procesem zgłoszeń. Zbudowano algorytm w oparciu o podany proces stochastyczny, który następnie został wykorzystany do budowy programu komputerowego Preforma 1.1, służącego do obliczania wartości grubości warstwy kompozytowej. Głównym celem niniejszej pracy było wykazanie skuteczności metody opartej na rachunku prawdopodobieństwa z uwzględnieniem wyników uzyskanych empirycznie. W celu udowodnienia skuteczności metody stochastycznej wyznaczania grubości kompozytu porównano realne grubości kompozytu uzyskanego na drodze doświadczenia z grubością kompozytu otrzymanego w oparciu o program symulacyjny NovaFlow&Solid i Preforma 1.1. Wyznaczone wartości grubości warstwy kompozytowej przy zastosowaniu autorskiego programu Preforma 1.1 okazały się porównywalne z wartościami otrzymanymi na staliwnych odlewach doświadczalnych, co świadczy o poprawności metody. Należy podkreślić, iż zaletą metody jest jej prostota w użyciu. Metoda ta pozwala ominąć opis skomplikowanych zjawisk wynikających z procesów dyfuzyjnych, uzależniając wyznaczanie grubości warstwy kompozytowej tylko od temperatury zalewania i czasów (ts) przebywania preformy powyżej Ts.

EN

The production of cast with composite surface layer is not complicated for technological reasons. However, the process of forming these layers is complex and depends on many technological and material factors. Because of great amount of factors, which influence the thickness, it is possible to use the theory of probability to calculate the thickness of composite layer in particular part of the cast. The composite layer can be 1 mm thick or 2 mm thick and so on. So we can deal with the composite layer formation process as with the process of forming some partial layers. It is assumed that these layers appears in turn, of course - with a certain probability. It means, that the composite layer is formed by a random variable. Its thickness is a the expected value of this random variable. It is assumed, that the layers appears in turn and in this way form whole composite layer, so we can treat this process as a simply stochastic process of entries. The preform temperature (concretely the preform time of staying in the temperature between Ts - Tl) was assumed as a basic factor which influences the thickness of composite layer. The algorithm (to determine the thickness of composite layer with the use of stochastic process) was worked out and used to build the program Preforma 1.1. The aim of researches was to prove the correctness of the method based on the calculus of probability thanks to the results of real casts. To prove the correctness of the stochastic method of determination the thickness of composite layer, the real thickness of composite formed during the real experiment were compared with the thickness of composite obtained from the simulation and program Preforma 1.1. In order to prove the correspondence between the preform times of staying in the temperature between Ts - Tl obtained from real experiment and simulation, the comparative analysis should be done in the same points of measurement. The goodness was obtained and allowed to use the results of simulation and real cast to build and check the mathematical model and computer program Preforma 1.1. The main conclusion is that the determined thickness of composite layer, with the use of program Preforma 1.1, are compatible with the thickness of composite layers measured during the experiment so this program is a useful tool to project the thickness of composite layers.

3

The determination of the thickness of composite layer

Baron C., Szajnar J.

Archives of Materials Science and Engineering

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2008

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Vol. 30, nr 1

45-48

EN

Purpose: In this article the thermal simulation of formation composite layer on steel model casting and real casts were presented and described. There is also shown a computer program to determine the thickness of composite layers with the use of stochastic process. The main aim of researches was to prove the correctness of the method based on the calculus of probability thanks to the results of real casts. Design/methodology/approach: Both the distribution of temperature in model casting and the course of temperature changes in the characteristic points of composite premould were determined for assumed changes of chosen technological parameters. The numerical calculations were done with the use of software NovaFlow&Solid 2.9 r81 and Preforma 1.1. Findings: The desirable thickness of composite layer depends on the parameter ts of process and the level of pouring temperature during the casting process. Research limitations/implications: Researches made possible to determine the thickness of composite layers and, thanks to it, to project the desirable composites. Practical implications: Thanks to obtained results there is a possibility to project the thickness of composite layers in concrete places with the help of only a few data.

4

The determination of the composite layer thickness with the use of software NovaFlow&Solid and Preforma 1.1

Baron C., Bartocha D., Szajnar J.

Archives of Foundry Engineering

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2008

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Vol. 8, iss. 1

5-12

EN

In this article the results of thermal simulation of formation composite layer on steel model casting were presented. The aim of researches was to determine the technological parameters of formation composite layer process for which it is possible to get good quality reinforcement layer with desirable thickness. Methodology. Both the distribution of temperature in model casting and the course of temperature changes in characteristic points of composite premould were determined for assumed changes of chosen technological parameters. The numerical calculations were done with the use of software NovaFlow&Solid 2.9 r81. Finding. Obtaining both the good quality and desirable thickness of composite layer depends on the parameters of process and the level of pouring temperature during the casting process. Research implications. Researches made possible to determine technological parameters directly influencing this process and criterions which should be kept by casting technology of this kind of casting. Practical implication and value. Thanks to obtained results there is a possibility to work out guidelines and rules of projecting the construction and the selection of technological parameters of casting with surface composite layer.

5

The determination of the thickness of composite layer for ball casting

Baron C., Bartocha D., Szajnar J.

Archives of Materials Science and Engineering

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2007

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Vol. 28, nr 7

425-428

EN

Purpose: In this article the results of thermal simulation of formation composite layer on steel model casting were presented. The aim of researches was to determine the technological parameters of formation composite layer process for which it is possible to get good quality reinforcement layer with desirable thickness. Design/methodology/approach: Both the distribution of temperature in model casting and the course of temperature changes in characteristic points of composite premould were determined for assumed changes of chosen technological parameters. The numerical calculations were done with the use of software NovaFlow&Solid 2.9 r81. Findings: Obtaining both the good quality and desirable thickness of composite layer depends on the parameters of process and the level of pouring temperature during the casting process. Research limitations/implications: Researches made possible to determine technological parameters directly influencing this process and criterions which should be kept by casting technology of this kind of casting. Originality/value: Thanks to obtained results there is a possibility to work out guidelines and rules of projecting the construction and the selection of technological parameters of casting with surface composite layer.

6

Thermal simulation of process formation composite layer on model casting

Baron C., Bartocha D., Gawroński J.

Journal of Achievements in Materials and Manufacturing Engineering

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2006

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Vol. 18, nr 1-2

51--54

EN

Purpose: In article the results of thermal simulation of formation composite layer on model cast steel casting process have been presented. The aim of researches was determination of technological parameters of formation composite layer process for which is possible to obtain good quality reinforcement layer with desirable thickness. Design/methodology/approach: For assumed changes of chose technological parameters, distribution of temperature in model casting as well as course of temperature changes in characteristic point of composite insert have been determined. Simulations have been carried out for two different materials of compositing element (insert) and three different pouring temperatures with software NovaFlow&Solid 2.9 r81. Findings: Obtaining good quality and with desirable thickness composite layer depends on process and level of heating during casting process. Research limitations/implications: Researches made possible to determination which technological parameters directly influent on this process and how criterions should be meet by casting technology of this kind of casting. Originality/value: Obtained results and their experimental verification will make possibility to form a basis for work out guidelines and principles for design technology of casting with composite layer on choose surfaces productions.

7

Symulacja cieplna procesu tworzenia warstwy kompozytowej na odlewie modelowym

Baron C., Szajnar J., Gawroński J., Bartocha D.

Archiwum Odlewnictwa

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2006

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R. 6, nr 21/1

17-32

PL

W artykule przedstawiono wyniki cieplnej symulacji tworzenia warstwy kompozytowej na staliwnym odlewie modelowym. Celem badań było wyznaczenie parametrów technologicznych procesów tworzenia warstwy kompozytowej, dla których można uzyskać dobrej jakości warstwę zbrojacą o pożądanej grubości. Dla założonych zmian wybranych parametrów technologicznych wyznaczono rozkład temperatury w odlewie modelowym oraz przebieg zmian temperatury w charakterystycznych punktach wkładki kompozytowej. Obliczenia numeryczne wykonano przy pomocy programu NovaFlow&Solid 2.9 r81. Uzyskanie warstwy kompozytowej dobrej jakości i o pożądanej grubości na odlewie jest uzależnione od procesu i poziomu temperatury zalewania w trakcie odlewania. Badania pozwoliły ustalić, jakie parametry technologiczne wpływają na ten proces i jakie kryteria powinna spełniać technologia odlewania tego typu odlewów. Dzięki otrzymanym wynikom można opracować wytyczne i zasady projektowania konstrukcji i doboru parametrów technologicznych wykonywania odlewów zbrojonych powierzchniowo.

EN

In article the results of thermal simulation of formation composite layer on model cast steel casting process have been presented. The aim of researches was determination of technological parameters of formation composite layer process for which is possible to obtain good quality reinforcement layer with desirable thickness. For assumed changes of chose technological parameters, distribution of temperature in model casting as well as course of temperature changes in characteristic point of composite insert have been determined. Simulations have been carried out for two different materials of compositing element (insert) and three different pouring temperatures with software NovaFlow&Solid 2.9 r81. Obtaining good quality and with desirable thickness composite layer depends on process and level of heating during casting process. Researches made possible to determination which technological parameters directly influent on this process and how criterions should be meet by casting technology of this kind of casting. Obtained results and their experimental verification will make possible to form basic to work out guidelines and principles for design technology of casting with composite layer on choose surfaces productions.