Page 11 - December

METALWORKING EQUIPMENT AND TOOLS METALWORKING EQUIPMENT AND TOOLS
Simulation model of a foundry complex for cast part from new alloys for modern technology, transfers a computer
A design engineer, developing a three-dimensional model of a

machine tool parts model of a part to a foundry technologist. The model of the part shows
surfaces to be machined, holes, possible radii of curvature, and various
thickenings. The casting technologist determines the position of the
model in the mold, allowances for machining, outlines the places of
installation of risers, gating systems, molding sands.
Then computer modeling of the casting manufacturing
technology is carried out: calculations of gating systems and metal
supply points; calculations of profits and places of their installation;
possible defects and their significance for the characteristics of
strength, density and reliability of the finished part.
When developing a computer model of the design of a part,
and then the casting technology of its manufacture, it is necessary
One of the main problems of the foundry at present is the creation of scientific foundations to take into account not only the chemical composition
for the design and CAD of structures of cast parts and their elements, which ensure the production of the alloy, its technological properties, but also
of proper castings with a minimum weight and configuration, regulated by the microstructure the characteristic features of its crystallization and
for machine parts (OST2-MT21-2-90), taking into account the current operating stress, strength solidification, the width of the solid-liquid zone during
and reliability. In the automated design of cast parts, the most important thing is to take solidification. For example, for ductile cast iron with spheroidal graphite - the
into account the complex relationships between the design of cast parts, their structure and amount of pre-shrinkage expansion, the rate of lowering of the level of liquid metal in the head
mechanical properties. This complexity causes limitations in the application of the quantitative and the nature of the location of shrinkage porosity. To solve these problems, it is necessary to
approach, which is associated with significant mathematical difficulties arising in the search take into account the thermophysical properties of the molding mixture and the density of the
for an optimal solution due to the huge number of changing parameters that characterize the mold packing, fluctuations in the pouring temperature of the alloy, and other factors affecting
manufacturing technology, design and properties of the cast part. It should be noticed that the quality of the casting as a whole.
numerical simulation on a computer cannot yet give specific data on the number, size and In this regard, the approaches to solving the problems of manufacturing large iron and
nature of the location of internal defects, and even more so it does not give an answer to the steel castings, namely, the installation of risers and metal supply points, given in the works of
expected mechanical properties of cast parts. V. M. Golod and V. A. Denisov [1], V. V. Desnitskiy [ 2, 3], etc.
Computer-aided design of the structure of a cast part is possible only with sufficiently As a result of the research carried out on the processes of forming a casting on the basis
substantiated initial data for compiling a software package. Such initial data in the development of computer modeling, it seems possible to proceed to experimental studies of the quality of
of a drawing of a part are the magnitude and nature of the acting load during operation, wall casting manufacturing; cutting out templates from different casting zones; investigation of
thickness, the ratio of the thicknesses of the mating walls, the distance between the vertical macro- and microstructure, location of porosity and non-metallic inclusions; determination of
walls in Z-shaped structural elements, the magnitude of the radii of the curvatures in the mechanical properties on samples cut from various casting zones, including those with a casting
inner corners of the mates, structure and possible defects. To obtain such initial data, we have crust.
developed a methodological basis for the design of elements of cast parts, which consists in Based on the results of experimental studies of the quality of a casting made using a
the characterization of research components, a set of tools and a sequence of research in the computer model, a designer and a casting technologist are finalizing the design of a cast part
process of solving this problem. and its manufacturing and control technology, which makes it possible to design a casting
The essence of the methodology for designing elements of cast parts is based on the complex using engineering logistics.
following basic provisions: Foundry complex engineering logistics represents solving a complex
● Scientifically grounded principles of designing elements analytical, organizational and technological problem. To successfully solve
of cast parts can be obtained only on the basis of this problem and achieve the goals of the project, the enterprise must
comprehensive studies of the crystallization process of implement a program of control actions, aimed at the formation of
alloys and structural properties of cast parts. Taking special working structures and the rational use of labor and intelligence
into account only one of these factors leads either of the members of the logistics engineering team. Rational project
to an overestimation of the mass of cast parts, management within the framework of logistics engineering is one
or to a decrease in their strength and reliability of the fundamental factors in achieving the goals. To achieve the
during operation; set goals, it is necessary to divide the project management work
● a comprehensive study of the crystallization into stages. This applies equally to both the existing and the newly
process of alloys and structural properties is created the enterprise.
recommended to be carried out on model samples, Project management of a foundry complex based on
including structural elements of cast parts; engineering logistics requires a deep understanding of the
● the quantitative relationship between the design essence and specifics of technological processes. Therefore, the
of cast parts, their structure and mechanical project should be implemented under the supervision of one or
properties is the basis for the design of technological a group of top managers of the enterprise with high professional
and reliable parts. This relationship should take into knowledge and experience. Unwillingness to admit mistakes,
account the composition of the alloy, the specific ignoring large and small problems inevitably leads to the loss
technology for making castings, the magnitude and of the company's competitive advantages in
nature of the operating loads during operation. the market.

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