Search procedure for optimal design and technological solutions to ensure dimensional and geometric accuracy of castings

Frolova, Liliia

doi:10.15587/2706-5448.2023.271860

Cited by 4 publications

(3 citation statements)

References 12 publications

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“…Modeling makes it possible to identify possible deviations from the specified values of these indicators [6][7][8] and to solve additional issues related to the development and improvement of the technological process [9]. The idea of such improvement at the stage of development or improvement of the technological process of casting in disposable sand molds, and, accordingly, the development or improvement of model casting equipment is presented in [10]. Its essence is that, by changing the design parameters of the elements of the sprue system or the variants of its arrangement on the basis of experimental planning methods, it is possible to obtain a mathematical description of the influence of the design parameters of the equipment on the formation of one or another indicator of the quality of finished castings.…”

Section: Introductionmentioning

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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Section: Introductionmentioning

confidence: 99%

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

Lysenkov,

Demin

2024

TAPR

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“…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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“…The result of the application of optimal or rational solutions in terms of molding is the formation of the quality of castings in terms of geometry and dimensional accuracy [27].…”

Section: Introduction the Object Of Researchmentioning

confidence: 99%

Improving technology for manufacturing casting case of truck clutch release cylinder

Demin

2023

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The object of research: Manufacturing technology of body castings for trucks using the example of a clutch release cylinder body made of gray cast iron with flake graphite EN-GJL-200. Investigated problem: Finding ways to reduce the weight and size characteristics of cast parts. The main scientific results: A mathematical model has been developed that has made it possible to determine the optimal compositions of alloying Cr/Ni – Cu/Ti complexes that ensure an increase in the grade of cast iron by increasing the tensile strength at elevated carbon contents. This makes it possible in the future to reduce the thickness of the walls of the castings, achieving a reduction in their weight and size characteristics The area of practical use of the results of the study: Automotive industry in terms of technology for manufacturing cast parts for trucks Innovative technological product: Improved technology for manufacturing the clutch release cylinder body due to optimization of melt technology and out-of-furnace processing allows for targeted selection of melt processing modes, ensuring an increase in the strength characteristics of cast iron for cast body parts, thereby moving from the EN-GJL-200 cast iron grade to the EN grade -GJL-250 and EN-GJL-300. The scope of the innovative technological product: Foundries of engineering enterprises, in particular those producing trucks, in which iron castings are produced

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Search procedure for optimal design and technological solutions to ensure dimensional and geometric accuracy of castings

Cited by 4 publications

References 12 publications

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

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

Improving technology for manufacturing casting case of truck clutch release cylinder

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