Reserves of resource saving in the manufacture of brake drums of cargo vehicles

Lysenkov, Vitalii; Demin, Dmitriy

doi:10.21303/2313-8416.2022.002551

Cited by 3 publications

(4 citation statements)

References 8 publications

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“…The increase in the amount of perlite under the action of these factors is justified, since Cr and V are strong carbide-forming elements, and the influence of Ti and Cu is twofold. At the same time, the ratio Cr:Ni=3.25:1 somewhat falls outside the range Cr:Ni=3:1-1 recommended by practice or the range given in [15], recommended for the manufacture of the same grade of cast iron for casting automotive parts -from Cr:Ni=2.2:1-2.4:1 to Cr:Ni=1.76:1. The introduction of additional vanadium and the associated increase in the amount of perlite does not contradict the conclusions of [16], where it is shown that the introduction of vanadium leads to an increase in the hardness of HB cast iron.…”

Section: Discussionmentioning

confidence: 70%

Procedure for selecting a rational technological mode for the processing of cast iron melt on the basis of graph-analytical processing of the data of serial smeltings

Nikolaiev

2022

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The object of research: cast iron grade DSTU EN 1561 (EN-GJL-200), used for the manufacture of body parts for mechanical engineering. Investigated problem: the choice of the technological mode of the process of producing cast iron under conditions of multifactorial influence on the formation of its microstructure. The main scientific results: A procedure for truncation of the influencing factors on the formation of the microstructure is proposed, which is a consistent reduction of data from serial smeltings to uniform conditions allowed by the actual data set. Common conditions mean the closeness of the chemical composition of the melt, which makes it possible to compare the effectiveness of the applied modifiers in combination with microalloying in terms of cast iron microstructure indicators. The proposed data truncation procedure made it possible, by creating conditions for comparing the efficiency of FeSi75 and FeSi65CaBaSr2 modifiers, to develop a rational technological regime for melt processing. It has been established that the compared modifiers have the same effect on the size of graphite – its content is (50–51) μm, however, the use of FeSi65CaBaSr2 in combination with an alloying complex (0.27 %Cr+0.083 %Ni+0.048 %Ti+0.155 %Cu+0.018 %V ) makes it possible to obtain an average amount of pearlite of 96 % in the microstructure. The area of practical use of the results of the study: the results obtained can be used in foundries or metallurgical shops of industrial enterprises as part of a general technology for producing cast iron of various grades, developed for cases of incomplete control of the quality of charge materials. Such a situation occurs, for example, when the charge is formed from dismantled armored vehicles that cannot be restored due to destruction on the battlefield. Innovative technological product: iron smelting technology that allows the possibility of minimizing the cost of smelting in terms of the use of modifiers and alloying ferroalloys The scope of the technological innovative product: technological regimes for the production of cast iron.

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Section: Discussionmentioning

confidence: 70%

Procedure for selecting a rational technological mode for the processing of cast iron melt on the basis of graph-analytical processing of the data of serial smeltings

Nikolaiev

2022

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“…The brake drum with sprue system elements is presented in Fig. 1, the form technology is given in [17]. To reduce the probability of the formation of a surface defect in the form of an open shell after removing the allowance, it is necessary to increase the size of the allowance.…”

Section: Research Results and Discussionmentioning

confidence: 99%

Improving the technology of manufacturing cast brake drums in pink sand molds

Lysenkov,

Demin

2024

TAPR

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The object of research in the paper is the production technology of casting «brake drum» from cast iron of the basic grade SCh20 according to GOST 1412-85 (DSTU EN 1561, EN-GJL-200). The existing problem is that due to the imperfection of the technological processes of manufacturing castings, final internal defects of a shrinking nature are possible. This can lead to a decrease in the strength and operational reliability of the drums, regardless of the chemical composition, which may meet the technical conditions and should provide the specified strength indicators according to the grade of cast iron. Based on the results of 3D modeling, it has been found that with the existing technology of manufacturing brake drum castings in one-time sand molds, final shrinkage defects are formed in the upper part of the casting. To eliminate this problem, a decision is proposed to increase the allowance for mechanical processing on the upper surface of the casting. The possible excess of the mass of the casting and excess consumption of the alloy that will occur when implementing this solution can be compensated by reducing the allowance on other surfaces based on their optimization by the method of dimensional chains and reducing the thickness of the casting wall. For this, a reduction in the carbon content in the alloy is proposed as a factor in increasing the tensile strength of cast iron. On the basis of 90 serial meltings in industrial conditions, the possibility of increasing the strength limit of cast iron by approximately 11 % by reducing the average carbon content in cast iron from 3.45 % to 3.4 % has been proven. The proposed solutions are the essence of improving the production technology of cast brake drums, which are produced by casting in one-time sand molds. The presented study will be useful for machine-building enterprises that have foundries in their structure, where iron is melted for the production of castings.

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“…The mathematical model obtained at step 5 can be represented by a regression equation in which the output vari-Engineering able ΔQ is determined from the nomogram (Fig. 3) according to the plan of the full factorial experiment 2 2 . The plan of the experiment is based on the factors φ and Δt, varied in the ranges φ = [φ min ; φ max ] and Δt = [Δt min ; Δt max ].…”

Section: Synthesis Of Optimal Air Flow Controlmentioning

confidence: 99%

“…Therefore, despite the well-known problems generated by cupola melting, for example, environmental hazards, it is problematic to abandon this process at this stage. It is cupola melting that makes it possible to obtain cast iron in large quantities with such quality indicators that are acceptable for the manufacture of machine body parts while minimizing the cost of their manufacture [1,2].…”

Section: Introductionmentioning

confidence: 99%

Experimental and industrial method of synthesis of optimal control of the temperature region of cupola melting

Demin¹

2023

Eureka: PE

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The object of research is the temperature regime of melting in a cupola. The synthesis of optimal control of such an object is associated with the presence of a problem consisting in the complexity of its mathematical description and the absence of procedures that allow one to obtain optimal control laws. These problems are due to the presence of links with a pure delay, non-additive random drift, and difficulties in controlling the process parameters, in particular, accurately determining the temperature profile along the horizons and the periphery of the working space of the cupola. The proposed conceptual solution for the synthesis of optimal temperature control allows the use of two levels of control: the level controller solves the problem of maintaining the constant height of the idle charge, and the problem of increasing the temperature of cast iron is solved by controlling the air supply to the tuyere box. It is shown that the problem of regulating the upper level of an idle charge can be solved by reducing the model of the regulation process to a typical form, followed by the use of the Pontryagin maximum principle. A procedure for the synthesis of optimal air flow control is proposed, which makes it possible to obtain the temperature regime control law on the basis of experimental industrial studies preceding the synthesis process. This takes into account the time delay between the impact on the object and its reaction, which makes it possible to predict the temperature value one step acharge, equal to the time interval during which the lower surface of the fuel charge reaches the upper surface of the level of the idle charge. A procedure for temperature profile control based on the use of D-optimal plans for selecting sensor installation points is proposed. Due to this, it becomes possible to determine the temperature profile of the cupola according to its horizons and the periphery of the working space of the cupola with maximum accuracy. The proposed synthesis method can be used in iron foundries equipped with cupolas, as it is a tool for studying a real production process, taking into account its specific conditions. This will allow developing or improving control systems for cupola melting, implementing different control modes: manual, automated or automatic

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Reserves of resource saving in the manufacture of brake drums of cargo vehicles

Cited by 3 publications

References 8 publications

Procedure for selecting a rational technological mode for the processing of cast iron melt on the basis of graph-analytical processing of the data of serial smeltings

Procedure for selecting a rational technological mode for the processing of cast iron melt on the basis of graph-analytical processing of the data of serial smeltings

Improving the technology of manufacturing cast brake drums in pink sand molds

Experimental and industrial method of synthesis of optimal control of the temperature region of cupola melting

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