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1

Zastosowanie oprogramowania CAD i CAE w celu zaprojektowania i doboru technologii odlewniczej dla odlewu z żeliwa szarego – tarczy hamulcowej

Fijołek A., Ryba J., Żak P., Lelito J.

Prace Instytutu Odlewnictwa

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2018

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Vol. 58, no. 3

153--169

PL

Opisano proces projektowania technologii odlewniczej pozwalającej uzyskać odlew żeliwny tarczy hamulcowej przy wykorzystaniu narzędzi CAD i CAE. Do obliczeń projektowych poszczególnych układów wlewowych zastosowano wzory powszechnie dostępne w literaturze dotyczącej branży odlewniczej. Obliczenia projektowe, proces projektowania w oprogramowaniu CAD – SOLIDWORKS oraz symulacje numeryczne w oprogramowaniu MAGMASOFT wykonano dla czterech różnych technologii wykonania odlewu. Przeprowadzona analiza pozwoliła na dobranie najkorzystniejszej technologii odlewniczej dla odlewu tarczy hamulcowej. Wybrana technologia odznacza się najlepszą konstrukcją układu wlewowego zarówno pod względem kształtu, jak i jego zasilenia. Ponadto wybrana technologia charakteryzuje się wysokim uzyskiem spośród pozostałych technologii, co prowadzi do ograniczenia kosztów związanych z procesem odlewniczym detalu tarczy hamulcowej.

EN

Describes the process of casting technology design that produces an iron casting brake disc using CAD and CAE tools. For design calculations of the individual filling and ventilating systems uses the formulas commonly available in the literature for the foundry industry. Design calculations, design CAD software – SOLIDWORKS and numeric simulations MAGMASOFT software made for four different technology. Analysis has allowed the selection of the best casting technology for cast iron brake disc. The selected technology is the best design of the casting system in terms of both shape and its powering. In addition, the selected technology is characterized by high yield out of other technologies, which leads to a reduction of the costs associated with the process of casting part – brake disc.

2

Study of Thermal Properties of Cast Metal-Ceramic Composite Foams

Gawdzińska K., Chybowski L., Przetakiewicz W.

Archives of Foundry Engineering

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2017

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Vol. 17, iss. 4

47--50

EN

Owing to its properties, metallic foams can be used as insulation material. Thermal properties of cast metal-ceramic composite foams have applications in transport vehicles and can act as fire resistant and acoustic insulators of bulkheads. This paper presents basic thermal properties of cast and foamed aluminum, the values of thermal conductivity coefficient of selected gases used in foaming composites and thermal capabilities of composite foams (AlSi11/SiC). A certificate of non-combustibility test of cast aluminum-ceramic foam for marine applications was included inside the paper. The composite foam was prepared by the gas injection method, consisting in direct injection of gas into liquid metal. Foams with closed and open cells were examined. The foams were foaming with foaming gas consisting of nitrogen or air. This work is one of elements of researches connected with description of properties of composite foams. In author's other works acoustic properties of these materials will be presented.

3

Evaluation of the Possibilities of Sodium Silicate Sands Application in Automated Hot-Box Process of Cores Shooting

Stachowicz M., Granat K., Obuchowski P.

Archives of Foundry Engineering

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2017

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Vol. 17, iss. 4

155--160

EN

The paper presents the results of preliminary research on the use of silica sands with hydrated sodium silicate 1.5% wt. of binder for the performance of eco-friendly casting cores in hot-box technology. To evaluate the feasibility of high quality casting cores performed by the use of this method, the tests were made with the use of a semiautomatic core shooter using the following operating parameters: initial shooting pressure of 6 bar, shot time 4 s and 2 s, core-box temperature 200, 250 and 300 °C and core heating time 30, 60, 90 and 150 s. Matrixes of the moulding sands were two types of high-silica sand: fine and medium. Moulding sand binder was a commercial, unmodified hydrated sodium silicate having a molar module SiO2/Na2O of 2.5. In one shot of a core-shooter were made three longitudinal samples (cores) with a total volume of about 2.8 dm3. The samples thus obtained were subjected to an assessment of the effect of shooting parameters, i.e. shooting time, temperature and heating time, using the criteria: core-box fill rate, bending strength (RgU), apparent density and surface quality after hardening. The results of the trials on the use of sodium silicate moluding sands made it possible to further refine the conditions of next research into the improvement of inorganic warm-box/hot-box technology aimed at: reduction of heating temperature and shot time. It was found that the performance of the cores depends on the efficiency of the venting system, shooting time, filling level of a shooting chamber and grains of the silica matrix used.

4

Effect of Microwave Heating on Moulding Sand Properties with Gypsum Binder

Paduchowicz P., Stachowicz M., Granat K.

Archives of Foundry Engineering

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2017

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Vol. 17, iss. 3

97--102

EN

The paper presents results of initial research on the possibility of applying microwave radiation in an innovative process of making casting moulds from silica sand, where gypsum CaSO4∙2H2O was acting as a binding material. In the research were compared strengths and technological properties of moulding mixture subjected to: natural bonding process at ambient temperature or natural curing with additional microwave drying or heating with the use of microwaves immediately after samples were formed. Used in the research moulding sands, in which dry constituents i.e. sand matrix and gypsum were mixed in the ratio: 89/11. On the basis of the results of strength tests which were obtained by various curing methods, beneficial effect of using microwaves at 2.45 GHz for drying up was observed after 1, 2 and 5 hours since moisture sandmix was formed. Applying the microwaves for hardening just after forming the samples guarantees satisfactory results in the obtained mechanical parameters. In addition, it has been noted that, from a technological and economic point of view, drying the silica sand with gypsum binder in microwave field can be an alternative to traditional molding sand technologies.

5

The Use of Rapid Prototyping Methods to Perform Flexible Pattern Mold for Compressor Turbine Casting in the Gypsum Molds

Wańczyk K., Gil A., Kowalski P.

Archives of Foundry Engineering

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2015

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Vol. 15, iss. 3 spec.

95--98

EN

There are many different casting technologies and their selection depends on the criteria to be met by a cast made. One of the less frequently used precision casting technology is a technology that uses gypsum block forms. From many years are available pre-mixed gypsum for the various alloys, and mold making technology itself can be based on melted wax models or models permanent removed from the mold after hardening the gypsum mix. In case of use permanent models to produce them may be used various types of flexible materials. This solution allows you to make complicated models that can be removed from the mold only by the fact that they are flexible and at the same time capable of large elastic deformations.

6

Piroliza utwardzonej żywicy fenolowo-formaldehydowej typu rezolowego - identyfikacja produktów metodą GC/MS

Kmita A., Roczniak A., Holtzer M.

Archives of Foundry Engineering

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2015

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Vol. 15, iss. 4 spec.

67--72

PL

Celem badań była identyfikacja głównych produktów pirolizy utwardzonego spoiwa stosowanego w technologii ALPHASET w zależności od temperatury rozkładu. Rozkład termiczny próbek prowadzono przy użyciu pirolizera w temperaturze: 700, 900 i 1100 °C w atmosferze helu o czystości 99,9999. Identyfikację produktów pirolizy prowadzono z wykorzystaniem techniki GC/MS. Okazało się, że temperatura 900 °C jest tą, w której powstaje najwięcej produktów pirolizy. W temperaturze 700 i 900 °C znaczny udział wśród produktów pirolizy ma dwutlenek węgla, który powstaje w wyniku rozkładu węglanu propylenu, będącego prawdopodobnie składnikiem mieszaniny estrów.

EN

The aim of the investigations was the identification of the main products of the pyrolysis of the hardened binder - applied in the ALPHASET technology - in dependence on the decomposition temperature. The thermal decomposition of samples was performed by means of the pyrolyzer at temperatures: 700, 900 and 1100°C in the atmosphere of helium (He) of the purity: 99.9999. This identification was performed by means of the GC/MS technique. It occurred that the temperature of 900°C is the one at which the highest amount of the pyrolysis products is formed. At temperatures of 700 and 900°C among the pyrolysis products there is a significant fraction of carbon dioxide, which is formed as the result of the decomposition of propylene carbonate, which is probably the component of the esters mixture.

7

Effect of Metal Oxides Nanoparticles on the Selected Strength Properties of Moulding Sand with Water Glass

Kmita A.

Archives of Foundry Engineering

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2015

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Vol. 15, iss. 3 spec.

33--38

EN

The modification of water glass with nanoparticles of metal oxides in organic solvents was attempted in the study. The results of investigations of moulding sands with water glass modified by nanoparticles of the selected metal oxides in organic solvents, are presented in the hereby paper [21]. Nanoparticles of ZnO, Al2O3 or MgO in methanol, ethanol or propanol solutions were applied as modifiers of binding agents. Colloidal solutions of the modifiers were introduced into water glass in the amounts of 3, 5 or 7 mass %. Influences of the applied modifier and organic solvents as well as the modifier fraction in the binder on the selected strength properties of moulding sands were tested. On the bases of the analyses of the obtained results the probable mechanism of the water glass modification with nanoparticles of metal oxides was proposed.

8

Research on Technology of Alloyed Copper Casting

Rzadkosz S., Kranc M., Garbacz-Klempka A., Piękoś M., Kozana J., Cieślak W.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 2

79--84

EN

The work presents experiment results from the area of copper casting technology and chosen examples of alloyed copper. At present, copper casting technology is applied in many branches of industrial manufacturing, especially in the sector of construction, communications, arms and power engineering. Alloyed copper, containing slight additions of different elements and having special physio-chemical properties, is used in a special range of applications. Copper technology and alloyed copper analyses have been presented, these materials being used for cast manufacturing for power engineering. The quality of casts has been assessed, based on their microstructure analysis, chemical content and the cast properties. During the research, special deoxidizing and modifying agents were applied for copper and chosen examples of alloyed copper; also exemplary samples were tested with the help of metallographic analysis, electrical conductivity and gaseous impurities research.

9

The quality of compressed air as the necessary condition the improving the process efficiency in foundry plants

Wrona R., Ziółkowski E., Smyksy K., Brzeziński M.

Archives of Foundry Engineering

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2013

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Vol. 13, iss. 4

107--111

EN

A foundry plant as a manufacturing system operates in accordance with the methods and principles making up the entire process of casting production, involving the use of machines and installations. One of the factors transforming the foundry plant’s static structure into the dynamic – processing structure is the compressed air. Practically each procedure making up the casting manufacturing process involves compressed air. Its sources include compressor machines connected to the receiving tanks, making up the compressed air transport installation. Two major aspects are to be addressed in compressed air management: the engineering and economic ones. The engineering aspect involves the manufacturing of compressed air with the required quality features and in the amount balancing its demand, whilst the economic aspect is associated with cost minimisation. This paper investigates the engineering aspects: air quality, with the main focus on air treatment processes to satisfy the constructional and operational requirements of air receivers present in the casting processes.

10

Shaping the Structure and Properties of High Quality Silumin Castings in Metal Molds Cooled with Water Mist

Władysiak R.

Archives of Foundry Engineering

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2013

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Vol. 13, iss. 2 spec.

98--105

EN

The paper presents some aspects of the theory and technology of high quality silumin castings in metal molds cooled pointed with water mist stream. The results of the work relate to improvement of the properties of silumin casts by affecting the cooling of the liquid silumin in gravity cast in metal mold and the possibility of controlling the solidification and crystallization of the casting. The high efficiency required from the cooling system is a consequence of an optimal selection of parameters of the generated mist and the maximum use of the phenomenon of water droplets evaporation on the surface of the cooled mold. The study showed that sequential spot cooling with use of water mist, characterized by a wide range of control means and a high maximum heat transfer efficiency, enables to control the flow of heat between the casting and the mold and it allows for a layered solidification leading to the realization of the entire cast solidification in the expected way: directional or simultaneous. Consequently, the results are: improvement of the quality of the castings as a result of the elimination of defects and significant reduction in shrinkage porosity in the casting, an increase of the homogeneity and fineness of the microstructure, about 25% increase in the mechanical properties.

11

Możliwości określenia zawartości lepiszcza w masach formierskich przy użyciu pola elektromagnetycznego

Nowak D., Granat K., Opyd B., Więcławek R.

Archives of Foundry Engineering

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2013

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Vol. 13, iss. 1 spec.

121--124

PL

W pracy zaprezentowano wyniki wstępnych badań nad możliwością określenia zawartości lepiszcza w klasycznych masach formierskich metodą mikrofalową. Przedstawione w pracy pomiary przeprowadzono z wykorzystaniem specjalnego stanowiska tzw. linii szczelinowej. Zawartość lepiszcza w masie formierskiej określano na podstawie badań mocy absorbowanej oraz mocy wyjściowej fali elektromagnetycznej. Jedną z głównych zalet proponowanej, nowej metody pomiaru zawartości lepiszcza jest krótki czas pomiaru.

EN

This paper presents the results of a preliminary study of the possibility to determining binder content in conventional moulding sands using microwave method. Measurements presented in this paper were carried out using a special work station - microwave slot line. Binder content in the moulding sands was defined by analyzing power absorbed and output power of an electromagnetic wave. One of the main advantage of the suggested, new method of binder content measurement is a short measuring time.

12

Mould components impact on structure and quality of elektron 21 alloy

Dybowski B., Kiełbus A., Jarosz R.

Archives of Foundry Engineering

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2013

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Vol. 13, iss. 2

17--23

EN

Magnesium alloys due to their low density and high strength-to-weight ratio are promising material for the automotive and aerospace industries. Many elements made from magnesium alloys are produced by means of sand casting. It is essential to investigate impact of the applied mould components on the microstructure and the quality of the castings. For the research, six identical, 100x50x20mm plates has been sand cast from the Elektron 21 magnesium casting alloy. Each casting was fed and cooled in a different way: one, surrounded by mould sand, two with cast iron chills 20mm and 40mm thick applied, another two with the same chills as well as feeders applied and one with only the feeder applied. Solid solution grain size and eutectics volume fraction were evaluated quantitatively in Met-Ilo program, casting defects were observed on the scanning electron microscope Hitachi S3400N. The finest solid solution grain was observed in the castings with only the chills applied. Non metallic inclusions were observed in each plate. The smallest shrinkage porosity was observed in the castings with the feeders applied.

13

Próba obniżenia energochłonności produkcji podzespołów przekładni planetarnej w oparciu o technologię odlewania z wykorzystaniem metod szybkiego prototypowania

Gil A., Kowalski P., Wańczyk K.

Journal of Research and Applications in Agricultural Engineering

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2012

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Vol. 57, nr 1

41-46

PL

W artykule przedstawiono propozycję obniżenia energochłonności wykonania półfabrykatów elementów przekładni planetarnej dzięki zastosowaniu technologii odlewniczej. W pierwszej kolejności dokonano analizy ilości skrawanego materiału dla wytwarzanych elementów w technologii wytaczania z pełnej bryły oraz dla surowych odlewów. Następnie opracowana została technologia odlewania poszczególnych elementów, dla której oprzyrządowanie wykonano przy zastosowaniu metod szybkiego prototypowania. Efektem prowadzonych prac było uzyskanie serii odlewów prototypowych, przeznaczonych do testów eksploatacyjnych oraz uruchomienie produkcji analizowanych podzespołów przekładni planetarnej.

EN

The article presents a proposal for reduced energy consumption level when making semi-finished components of the planetary gear by casting technology. First, an analysis was made of the material volume removed from elements machined by boring from a full block as compared with raw castings. Then the casting technology was developed for different elements, for which tooling was made by the rapid prototyping technique. The result of the work was obtaining a series of prototype castings intended for field testing, and launching the production of the analysed components of the planetary gear.

14

Overview of activities on the internet devoted to casting technology

Wilk-Kołodziejczyk D., Regulski K., Dziaduś-Rudnicka J., Kluska-Nawarecka S.

Archives of Foundry Engineering

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2012

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Vol. 12, iss. 2

245-250

EN

Article present various forms of transfer of information available on the Internet. An attempt was made to show the possibility of such a selection of the knowledge sources that, taking into account user preferences, would arouse his interest, showing in parallel the intended substantive content. This commitment is shown in the context of the current assumptions of building a platform dedicated to support the needs of production processes in foundry and metallurgy.

15

Investigations of properties of wax mixtures used in the investment casting technology - new investigation methods

Zych J., Kolczyk J., Snopkiewicz T.

Archives of Foundry Engineering

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2012

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Vol. 12, iss. 3

133-138

EN

The results of testing of the selected group of wax mixtures used in the investment casting technology, are presented in the paper. The measurements of the kinetics of the mixtures shrinkage and changes of viscous-plastic properties as a temperature function were performed. The temperature influence on bending strength of wax mixtures was determined.

16

Possibilities of utilizing used moulding and core sands by microwave treatment

Granat K., Nowak D., Stachowicz M., Pigiel M.

Archives of Foundry Engineering

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2011

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Vol. 11, iss. 1

35-38

EN

The paper presents a semi-industrial reactor designed for microwave utilization of waste moulds and cores made of moulding sands prepared in furane resin technology. It was found that a possibility exists of effective incinerating this way prepared residues of cores separated from moulding sands or waste moulds left after casting. The preliminary tests evidenced that microwave heating is an effective way of disposing waste moulding sands and the applied apparatus permits effective control of the microwave heating process. The special structure permitting rotations of charge material and proper selection of the generators working cycles guarantee significant speeding-up the process and its full stabilisation. Application of microwave heating for utilization of waste moulds and cores containing synthetic resins as binders ensures significant and measurable economical benefits resulting from shorter process time.

17

Application of time-series analysis for prediction of molding sand properties in production cycle

Perzyk M., Maciejak S., Kozłowski J.

Archives of Foundry Engineering

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2011

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Vol. 11, iss. 2

95-100

EN

Time-series analysis is characterized, as a data mining tool which facilitates understanding nature of manufacturing processes and permits prediction of future values of the process parameters or production results on the basis of the past data, recorded in regular intervals. The main methods and problems of the time-series analysis are presented. The authors' research results, based on green molding sand properties data collected in a foundry with Disamatic molding line, are presented. The work was aimed at finding optimal settings and models of the time-series analysis for that data as well as detection of possible periodicities appearing in the sand properties. It is concluded that although the time-series analysis requires individual approach to each particular problem, some general recommendations can be also formulated. It can be a useful tool for analysis and predictions of outcomes of foundry processes.

PL

Scharakteryzowano analizę szeregów czasowych, jako narzędzia eksploracji danych, umożliwiającego lepsze rozumienie natury procesów produkcyjnych oraz pozwalającego na przewidywanie wyników produkcji na podstawie danych z przeszłości, rejestrowanych w regularnych odstępach. Przedstawiono główne metody i problemy tej analizy. Zaprezentowano wyniki własnych badań dla danych zawierających właściwości wilgotnych mas formierskich, zebranych w odlewni z linią formierską Disamatic. Badania te miały na celu znalezienie optymalnych ustawień i modeli analizy szeregów czasowych oraz wykrycie ewentualnych okresowości występujących we właściwościach masy. Stwierdzono, że jakkolwiek analiza szeregów czasowych wymaga indywidualnego podejścia do każdego konkretnego zagadnienia, to jednak możliwe było także sformułowanie pewnych zaleceń ogólnych. Analiza szeregów czasowych może być użytecznym narzędziem dla analizy i prognozowania wyników procesów odlewniczych.

18

Acquisition of technology knowledge from online information sources

Kluska-Nawarecka S., Wilk-Kołodziejczyk D., Dziaduś-Rudnicka J., Smolarek-Grzyb A.

Archives of Foundry Engineering

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2011

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Vol. 11, iss. 3

107-112

EN

The article discusses problems related with the search of information from open sources, particularly on the Internet. Specific area of concern is searching for technical knowledge in the area of metalcasting. The results of ongoing experiments were given, to serve as a basis in identification of the opportunities to improve the process of searching through determination of own research plans.

19

Thin wall ductile iron casting as a substitute for aluminum alloy casting in automotive industry

Górny M.

Archives of Foundry Engineering

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2009

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Vol. 9, iss. 1

143-146

EN

In paper it is presented thin wall ductile iron casting (TWDI) as a substitute of aluminium alloy casting. Upper control arm made of ductile iron with wall thickness ranging from 2 - 3.7 mm was produced by inmold process. Structure, mechanical properties and computer simulations were investigated. Structural analysis of TWDI shows pearlitic-ferritic matrix free from chills and porosity. Mechanical testing disclose superior ultimate tensile strength (Rm), yield strength (Rp0,2) and slightly lower elongation (E) of TWDI in comparison with forged control arm made of aluminium alloy (6061-T6). Moreover results of computer simulation of static loading for tested control arms are presented. Analysis show that the light-weight ductile iron casting can be loaded to similar working conditions as the forged Al alloy without any potential failures.

20

The influence of copper on the microstructure and selected parameters of duplex cast steel

Stradomska J., Stachura S., Stradomski Z., Soiński M. S.

Archives of Foundry Engineering

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2009

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Vol. 9, iss. 1

87-90

EN

Technological problems related to mastering the production of castings made of ferritic-austenitic cast steel (duplex type), i.e problems related to low carbon content (Cmax 0.03%) and high hot cracking susceptibility due to phenomena taking place during solidification and cooling of castings, cause that this material, although attractive due to its price and improving company prestige, is rarely produced in Poland. The undertaken attempts have mainly dealt with GX2CrNiMoCu25-6-3-3 grade containing copper due to the requirements of power industry which is the main possible customer with respect to the elements made of duplex cast steel. The authors of this paper have thought it reasonable to present selected aspects of microstructural and mechanical properties for the two cast steel grades described in the PN-EN 10283:2002 Standard, which differ only by Cu addition. The examinations concerned mainly the as-cast condition, because it is decisive for the defective production. It has been shown that the weak austenite-forming copper exerts a strong influence on the primary structure of cast steel, resulting in precipitating the [...] austenite within ferrite, where the austenite is crystallographically dependent on the matrix. The GX2CrNiMoCu25-6-3-3 cast steel in supersaturated state is characterised by Charpy V-notch impact energy lower by about 30% than for the cast steel grade without Cu addition.