PROSPECTS FOR THE DEVELOPMENT OF MODERN FOUNDRY

Kokareva V.V., Malykhina O.N., Smelov V.G.

(Samara State Aerospace University named after S.P. Korolev, (National Research University), Samara, RF)

The implementation of large projects in the field of mechanical engineering and foundry production can be carried out in various ways and on different scales. It is possible to form a state development program, as outlined, for example, in the Concept for Forming a State Comprehensive Program for the Development of Russian Engineering. This program was prepared by the Russian Union of Mechanical Engineers under the leadership of the Chairman of the Union S.V. Chemezova (head of the Russian Technologies Corporation). It is difficult for foundry workers to create a single program, since foundry production provides for different branches of engineering, and everywhere a different range of products is needed, which means that different technologies and equipment have their own requirements and features. Therefore, for the foundry, programs and projects are expedient in relation to individual branches of engineering.

The non-profit partnership "Union of Foundry Workers of St. Petersburg" has developed and plans to implement a project to create a modern foundry and mechanical complex in relation to the localization of the production of components for assembly plants of foreign car brands operating in Russia, factories of electrical household appliances, as well as for the supply of components to Russian factories automotive, tractor, household appliances and the European market.

An integrated approach to the creation of such production is as follows.

A modern foundry and mechanical production is being created as part of a project called "Multifunctional technopark with a foundry and mechanical production for localizing the manufacture and supply of components for mechanical engineering (automotive and household appliances) and a training center."

Goals this project:

– develop and implement an individual plan for the development of foundry and mechanical enterprises, the creation of competitive production of foundry products for the domestic and foreign markets: from the modernization of the organization and management system, logistics, sales and quality, to the actual modernization of production and personnel training;

– to create a multifunctional technopark on the basis of an existing enterprise to provide all related services to foundry and mechanical plants (laboratory, testing, certification, service department), ensure their specialization, bring to the implementation of domestic developments of scientists, technologists and designers.

As part of our project, which is fully consistent with the goals of the Russian foundry modernization program, it is planned tosolve the problem of increasing the efficiency of multi-product unique and small-scale production by creating a technological complex using modern methods of organization and management in conjunction with appropriate equipment that can ensure complete processing of specified products with increased labor productivity and approaching technology automation. In this case, we are talking about the organization of such production complexes that have high-tech means of computer modeling, rapid prototyping and technologies for the direct production of high-tech engineering products.

Taking into account the need to maximize the economic effect from the introduction of rapid prototyping and direct production technologies, several laboratories should be created in the structure of these complexes, responsible for the development and application of the following interrelated technologies and areas: “Development and management of projects”, “Design and technological preparation of production”, "Rapid Prototyping and Direct Manufacturing", "Decision Center", "Production based on CNC equipment".

Figure 1 -Scheme of the complex

For several decades, prototyping technologies and direct tool-free production technologies at leading Western enterprises have been an indispensable stage in the development and pre-production of any new product in almost all branches of mechanical engineering: aviation industry, automotive industry, instrument making, electrical industry. They allow not only to evaluate the appearance of the product being developed, but also to check the structural elements, its ergonomics, assembly, carry out the necessary tests, make a master model for subsequent casting, and much more. When using these technologies, the long and laborious stage of manufacturing prototypes manually or on CNC machines is practically eliminated. The world practice of using these technologies proves that prototyping of products at the design stage makes it possible to reduce the time of development and technical preparation for the production of new products by 2–4 times.

Figure 2 - The structure of integrated technologies

NASA experiments concluded that polymer models made using laser stereolithography technology can be tested in a wind tunnel at high speeds up to supersonic. Economic analysis, conducted at TsAGI, showed that aerodynamic models obtained by stereolithography, in comparison with a typical model, can reduce labor intensity by up to 20-60%, cost by 25-75%, and manufacturing time by 2-5 months. In this case, the accuracy of the model is within 100 µm, the roughness Ra= 2-5 µm. That is, 3D manufacturing of parts/prototypes in conceptual modeling can be widely used at the initial stages of development of aerospace engineering, engines, cars, trains and other complex, science-intensive machines.

Integrated technologies are based on an organic combination of the latest achievements in various fields of science, engineering, technology, computer science, materials science, etc., the use of which ensures the rapid production of a new product with a fundamentally different level of functional, aesthetic and environmental properties, which guarantees it high competitiveness in the market.

Thus, the goal of modern developing production, in particular, foundry, is to create a complex of collective access to high-tech computer modeling tools, rapid prototyping and technologies for direct tool-free production of high-tech engineering products using advanced technologies and innovative equipment of "smart production" high-tech engineering.

Current and prospective results from the use of the presented integrated engineering technologies will allow:

· To improve the quality and competitiveness of products due to the possibility of producing functional prototypes at the earliest stages of development, analyzing the product from the point of view of the consumer, functionality, maintainability, etc.

· Reduce product development and production cycle time through the use of innovative technologies in preparation for production, tool-free manufacturing (growing) of tooling, the introduction of new foundry technologies based on rapid prototyping systems.

· To carry out technical improvement of manufactured products by reducing or completely eliminating technological restrictions on the complexity, accuracy and quality of manufactured products or their components.

A set of measures for integration modern technologies described above, we implemented on the basis of the laboratory of additive technologies of the SSAU named after Academician S.P. Queen. As part of the prototyping laboratory, the following tasks are solved:

• design of design documentation;
• design and adjustment of 3D models of products according to ready-made drawings;
• translation design documentation in electronic form 2D drawings and 3D models;
• production of polymer prototypes of products;
• creation of silicone injection molds;
• rapid production of product samples;
• production of small batches of products (casting in silicone molds);
• design and manufacture of molds;
• mold spillage analysis and materials science;
• production of prototypes and small batches of parts on CNC equipment;
• measurement and control of the obtained prototypes.

In particular, we have done the following:

A technique has been developed for designing TC for the manufacture of silicone molds using various methods for forming parting surfaces;

Vacuum casting into elastic molds was performed, prototypes and batches of plastic parts were obtained, wax models were obtained without the use of traditional technological equipment;

The metal was melted and poured in an induction furnace in a vacuum;

By the method of rapid prototyping, experimental parts of the combustion chamber of a gas turbine engine were obtained, in SA D/C AM system NX built models of parts and in C AE ProCast system the process of pouring metal into a ceramic mold is simulated.

Figure 3 - Elements of integrated production

Shortcut http://bibt.ru

§ 5. Ways to improve the quality of castings

Improving the quality of castings is ensured by carrying out a whole range of organizational and technical measures in the foundry.

The composition of the molding sand is important for improving the quality of manufactured castings. Providing the site with high-quality raw materials, supplying the recycled mixture to mixers in a cooled state, high-quality separation and screening of the used mixture, accurate dosing of components, in particular the binder, have a positive effect on improving the quality of castings. Great importance has a well-established regular control of the properties of molding materials in the workshop laboratory and, first of all, control of strength and gas permeability.

The quality of castings also depends on the state of the technological equipment. Wooden model kits are warped, with cracks do not contribute to the achievement of dimensional accuracy. Warping of flasks during the manufacture of molds, especially large ones, is unacceptable; this leads to a redistribution of loads in the parting plane, collapse of the mold, and leakage of metal from it.

Compaction of the mold must be carried out strictly in accordance with the technical instructions. In the manufacture of large molds, it is advisable to use cold-hardening and liquid mixtures that do not require compaction. Low surface roughness of castings is ensured by the use of non-stick mold coatings.

Of great importance for obtaining high-quality castings is the continuous improvement of the skills of the brigade molders at various courses.

It is important to have well-established control over the performance of all operations for the manufacture of casting molds in the workshop, to correctly follow the instructions of technological instructions, and to improve sanitary and hygienic working conditions.

The introduction of the latest achievements of science and technology, the improvement of the culture of production in the foundry are an indispensable condition for the production of quality products.

test questions

1. Name the features of the formation of castings.

2. Tell us about the methods of quality control of molds, cores used in the foundry.

3. List the casting defects that occur during manual molding.

4. Name the activities that improve the quality of castings.

CONFERENCES SEMINARS EXHIBITIONS 121

IMPROVING TECHNOLOGY AND INCREASING THE EFFICIENCY OF FOUNDRY PRODUCTION

The scientific and practical seminar "IMPROVING TECHNOLOGY AND INCREASING THE EFFICIENCY OF FOUNDRY PRODUCTION" was held on October 7-10, 2008 within the framework of the XII International Forum "Russian Industrialist".

The forum brought together industrialists and entrepreneurs from many regions of Russia, as well as representatives of countries near and far abroad. Every year this seminar becomes more and more representative, and its program is supplemented by the most relevant topics and directions that meet the requirements and requests today. The holding of the forum is one of the most important events in the business calendar of St. Petersburg and all of Russia.

In 2008, the agenda of the forum included a discussion of the most important issues related to the introduction of innovative technologies and the development of small business. In the address of the Governor of St. Petersburg V.I. Matvienko to the participants and guests of the International Forum "Russian Industrialist" it was noted that its subject matter fully meets the interests of the city (metropolis), the objectives of its industrial policy, aimed competitive world-class products.

An important event included in the program of the event was the holding of a scientific and practical seminar "Improving technology and increasing the efficiency of foundry production", which was held under the scientific guidance of prof., Dr. tech. Sciences Tkachenko Stanislav Stepanovich - President of the Association of foundry workers of St. Petersburg.

The seminar was attended by experts in the field of foundry and metallurgy: FGUTT "PO" Oktyabr", OJSC "Rostvertol", OJSC "NPK "Ural-vagonzavod", CJSC "Kazan Giproniyaviaprom", CJSC "Tekhnologiya-M", OJSC "BiKZ ”, OJSC GPNII-5, OJSC AK OZNA, LLC Polygon, KomMod, Escalada, Rontal-Impex, SevZapEnergo, TsNIIM, as well as the State Polytechnic Institute ( Technical University), Department of Automation of Technological Processes and Productions of the St. Petersburg State Mining Institute (Technical University), etc.

A number of reports at the seminar aroused particular interest of the participants: “New materials and foundry technologies (G.A. Kosnikov, GPTU), “Computer analysis of foundry technology - problems and prospects” (V.M. Golod, GPTU), “Cast aluminum alloys and technologies for obtaining high-quality castings from them "(A.A. Abramov, TsNIIM),

“Complex modifiers for steel casting” (N.V. Ternovy, “KomMod”), “Computer modeling system “Polygon” (E.A. Ishkhanov), “Modern technologies of iron casting” (S.S. Tkachenko, GPTU), “The experience of the enterprise in improving the technology of injection molding” (S.L. Samoilov, “Escalada”), “New foundry steels and technologies for obtaining high-quality castings from them” (G.A. Shemonaeva, TsNIIM), “Modern technologies of titanium casting” (A.M. Podpalkin, TsNIIM), “Computer analysis of model casting technology and the use of exothermic materials to improve the quality of castings” (D.A. Lukovnikov, Rontal-Impex), “Casting technologies using vacuum film molding” (V.D. Ryabinkin, TsNIIM), “Experience in the manufacture of pattern equipment” (T.N. Gavrilova, “SevZapEnergo”), “Possibilities of using modern metal hardness testers and eddy current flaw detectors” (M.Yu. Koroteev, “Konstanta” ) and etc.

On October 9, an off-site meeting was held at the Contact Network Fittings Plant, where the problems “Production of investment casting” and “Production of casting using gasified models” (A.A. Lisova) were discussed.

On the final day of the seminar on October 10, an exchange of experience took place on the considered problems of foundry production and a discussion of the speeches of the seminar participants.

In the decision of the seminar, it was noted that the main procurement base of machine building is foundry production, the development of which depends on the level of the machine-building complex as a whole. The machine-building complex of Russia includes about 7,500 enterprises. The share of mechanical engineering in the total industrial output is about 20%, including 2.5% of machine tool and instrument making.

At present, there are about 1,650 foundries in Russia, which, according to peer review, produced 7.68 million tons of castings in 2006, including cast iron - 5.28 million tons, steel - 1.3 million tons, non-ferrous alloys - 1.1 million tons.

In 1980, in the USSR, the volume of production of castings from alloys of ferrous and non-ferrous metals amounted to 25.8 million tons. - whether the technical potential (capacity) is more than 2 million tons. ^ The foundry production of the Minstankoprom was considered the flagship of the USSR in the production of iron castings, especially large ones. During this period, foundries out- | advanced technological processes of melting, 5 shaping, finishing operations were used. In the foundry

122 CONFERENCES SEMINARS EXHIBITIONS

about a dozen research institutes of all-Union significance worked in production. The Minstankoprom produced 70,000 metal-cutting and 20,000 forging and pressing machines.

The production volumes of cast billets are in proportion to the volumes of production of machine-building products, since the share of cast parts in cars, tractors, combines, tanks, aircraft, etc. is 40-50%, and in metal-cutting machines and forging equipment reaches 80% of the mass and up to 25% of the cost of the product.

A sharp decline, since the 1990s, in the production of metal-cutting, woodworking machine tools and forging and pressing equipment, as well as power equipment for heavy engineering, shipbuilding, tractors, military equipment, etc., has led to a decrease in the production of castings in Russia from 18.5 million tons in 1991 to 4.85 million tons in 2000. Specialized centrolite plants for machine tool building with a total capacity of about 1 million tons of castings per year, created in the 1970s, could not stand the competition, lost orders and practically ceased their activities. Foundries working on the surviving mills

construction plants, in 2006 produced (according to expert estimates) 190-195 thousand tons of castings for own production and external customers.

A rather complicated situation has developed. If orders for machine tools now appear, foundries will not be able to produce high-quality, competitive castings, and none of the remaining foundries can produce castings weighing more than 30 tons. There are almost no highly qualified foundry specialists left in the industry, both workers and engineers, and most of the research institutes have been liquidated.

There is an urgent need for reconstruction of foundry shops, which should be carried out on the basis of new, environmentally friendly technological processes and materials, progressive melting, mixing-preparation and shaping equipment, ensuring the production of high-quality castings that meet European and international standards.

S.S. Tkachenko, I.N. Beloglazov

St. Petersburg State Mining Institute (Technical University)

HN>UU fcxrnuSiOft ihOuSTl

Official representative of Aluminco s.a. in Russia, EvrAzMetall-Center

ALUMINCO S.A. formed in 1982 in Greece. During its existence, it has become one of the largest companies in Europe in the field of aluminum production. It supplies its products to more than 60 countries of the world. Production capacity companies allow to produce up to 7000 tons per year aluminum profile, up to 1000 tons of aluminum castings, up to 50000 pcs. aluminum sandwich panels.

The production and technology group includes:

extruder with a capacity of 7000 tons of profiles per year; Foundry;

painting line with preliminary anodizing; sandwich panel production line; bending line;

assembly shops;

tool line for the production of matrices; design department; design studio.

The quality of the products is certified by ISO 9001, QUALICOAT and BUREAU VERITAS. ALUMINCO S.A. campaign products:

7 profile systems designed for the manufacture of windows, doors, facades, office partitions, etc., in various combinations, which can work in both hot and cold climates, with various wind loads;

door aluminum sandwich panels of about 1000 different configurations, intended for use both for internal and external doors;

cast aluminum gratings; gates and wickets made of cast aluminum; Street lights; outdoor and garden furniture; visors over entrance doors; stair railing;

small architectural forms (columns, pylons, cornices, ports, etc.).

In 1996, for the first time in Russia, elements of decorative design of internal facades were used during the construction of the Okhotny Ryad shopping center on Manezhnaya Square.

Subsequently, the products of ALUMINCO S.A. were used in the construction of various shopping centers, residential buildings, settlements and other urban and social facilities.

Our website: www.aluminco.ru

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UDC 621.74

MODERN FOUNDRY TECHNOLOGIES

B. S. Glazman

Don State Technical University, Rostov-on-Don, the Russian Federation

UDC 621.74 MODERN FOUNDRY TECHNOLOGIES

Don State Technical University Rostov-on-Don, Russian Federation

The technologies for manufacturing castings, methods of automation of foundry production, the composition of foundry conveyors, the use of a protective coating to improve the quality of manufactured products are considered.

Keywords: foundry, castings, chill mold, chill conveyor, molding, molding line

The article considers the technologies of making castings, methods of automation of foundry production, the composition of foundry conveyors and the application of protective coatings to improve the quality of manufactured products.

Keywords: foundry, castings, shell mold, permanent mold conveyor, block mold, block mold conveyor, forming, molding line

Introduction. Foundry production is one of the main procurement bases of mechanical engineering. Foundry production has a high metal utilization rate - 75-95%. Russia ranks third in the world in terms of the total production of cast billets after such large producing countries as China and the USA.

Numerous casting methods are used in the industry. To increase labor productivity, they seek to use in-line production, full mechanization and automation of foundry production.

Casting technologies. At present, in the manufacture of castings by molding, molding lines and pouring machines are used, which make it possible to produce a large number of forms with high accuracy with a small number of staff.

Fig.1 Molding line HWS: 1,4,11 - plate; 2 - rack; 3 - clamp; 5,9,10,12,14 - guide; 6.8 - mount; 7 - disk; 13 - bushing; 15 - clamp.

Rice. 2 General form automatic molding line Disa

The Disa molding line includes a shuttle-type sandblast molding machine that pulses the flaskless molds onto the conveyor. In the pouring section, the automatic pouring unit (5) fills the molds with the melt. Then the castings are cooled and transferred to a cooled knockout drum, where the castings are separated from the mixture, lumps are crushed, and the mixture and castings are finally cooled. The next step is the homogenization of the circulating mixture, which enters the syringe for the final preparation of the mixture and into the mixer, where it is transferred with refreshing materials and a high-ranking mixture is obtained. The resulting mixture is transferred to the molding machine.

Castings enter the shot blast machine (4) through an adapter (3) for surface treatment. Then the painting, quality control and warehousing operations take place.

At present, special casting methods are used in the industry, for example, die casting. This method allows to obtain more precise castings with stable dimensions. The minimum physical and chemical interaction between the casting metal and the mold contributes to the improvement of the quality of the casting surface, the absence of burn marks. Heat is quickly removed from the casting, which leads to its rapid hardening and provides an increase in mechanical properties.

Mechanization and automation technological process die casting provides an increase in labor productivity, stability of technological regimes, improvement in the quality of the casting and an increase in the economic efficiency of the production process.

On the industrial enterprises chill conveyors are used. On the trolleys of a horizontally closed conveyor, a mold is installed for one or more different castings, which is an indicator of the productivity of foundry equipment.

Fig 3. Rotary chill machine: 1.2 - plate; 3 - shaft; 4 - pusher.

Rice. 4. Vertically closed mold conveyor: 1 - wheel; 2,3 - chain; 4 - tray; 5 - box;

6 - nozzle; 7 - spray gun; 8 - tank; 9 - transmission.

In the mold mold of the conveyor (Fig. 4), the cover opens automatically, and the castings from the mold through the tray (4) fall into the box (5). On the lower branch of the conveyor, open molds are cooled by air from nozzles (6), then painted with a spray gun (7) from a tank (8).

The main operations of mold casting are the opening of the mold, the extraction of cores and castings, the application of a refractory coating, the installation of cores, the locking of the mold, the pouring of the melt. All operations are performed by the mechanisms of a chilling machine or a foundry complex, which is controlled by a worker-operator. When automating the chill conveyor, the mechanisms are controlled by a computer.

With serial and small-scale production for large castings of complex configuration, it is effective to use automated chill molds. In mass and large-scale production of small and medium-sized castings - automatic foundry complexes and automatic lines.

Fig.5 Schemes of automated foundry complexes for mold casting: a - for complex castings; b - for simple castings.

Figure 5a shows an automated casting complex for complex castings. The melt from the dispenser (1) is poured into the mold (2). Sand cores from the magazine (4) are installed in the mold with a manipulator (3). After hardening and opening of the mold, the castings are removed by the manipulator (6) and fed into the press (8) to harden the gating system.

Finished castings fall into the container (7), and then are transported along the conveyor (5) for processing. The melt from the melting units is fed into the dispenser along the monorail (9) by ladles. Manufacturing process operated by operators.

On fig. 4b shows an automated casting complex for simple castings. The melt from the dispenser (1) is poured into the molds installed on the machines (2). After the casting hardens and the mold opens, the casting is removed by the manipulator (4) and transferred to the container (3). The complex is controlled by the operator from the remote control.

In mass and large-scale production, specialized lines are used, designed both for the manufacture of one casting, and several castings of the same type.

Such lines include melting units, vehicles for filing

melt to loading devices, units for processing castings, vehicles for waste disposal, equipment for cleaning castings, installations and devices for quality control of castings. The lines are characterized by high performance and energy efficiency.

Fig.6 Scheme of an automated control system for the casting process

under pressure by computer

Figure 6 shows a diagram of an automated control system for the technological process of injection molding using a computer.

Automated system functions as follows. The signals from the parameters of technological processes (T) are sent to the switches (K), and then to the ADC and then to the control computer serving all the injection molding complexes. The casting quality control system (QCS) sets the numerical values ​​of the functions of quality indicators (T) from the parameters of the technological process (objective function) and transmits the computer through the switch K3 and ADC3. A computer based on a program and a mathematical model of the technological process, linking the target function, constant and variable (adjustable) parameters of the injection molding process, develop optimal values ​​of the adjustable parameters. Through the system feedback, including the switch K2 and ADC2, the control signal is transmitted to the system of regulators (p), which act on the actuators of the casting machine.

The operation of casting machines and units takes place under heavy loads and various levels of temperature, in aggressive environments and vacuum.

Used in industry various methods coatings using a variety of materials (metals, alloys, ceramics, plastics), as a result of which the physicochemical state of the surface layer of the workpiece differs from the main material of the part. These include surfacing and sputtering, electrolytic and chemical coatings, coatings with polymeric materials.

The galvanizing method is widely used in enterprises. The galvanizing process is carried out by vibration processing, which is fully automated. The method of electroplating is also widely used, providing high quality product surface.

Conclusion. Automation of foundry production using modern technologies and equipment increases the level of productivity of enterprises, the competitiveness of manufactured products and the efficiency of the industry as a whole.

Bibliographic list.

1. Gini, E. Ch. Technology of foundry production. Special types of casting / Gini E. Ch., Zarubin A. M., Rybkin V. A. - 3rd ed., Moscow: Academy, 2008. - 352 p.

2. Glazman, B. S. Automated and robotic casting. Finishing casting / B. S. Glazman // Monograph. - Rostov-on-Don: DSTU Publishing Center, 2014. - 88 p.