DOI: https://doi.org/10.32515/2664-262X.2020.3(34).163-169
Automation of Batch Casting of Cast Iron Melts in the Chill Mold in the Production of Castings of Machine Parts for the Mining Industry
About the Authors
Viktor Lomakin,Associate Professor, PhD in Technics (Candidate of Technics Sciences), Central Ukraіnian National Technical University, Kropyvnytskyi, Ukraine
Viktor Pukalov, Associate Professor, PhD in Technics (Candidate of Technics Sciences), Central Ukraіnian National Technical University, Kropyvnytskyi, Ukraine
Viktor Dubodelov, Professor, Doctor in Technics (Doctor of Technics Sciences), Physical and technological Institute of metals and alloys academy of sciences of Ukraine, Kyiv, Ukraine
Maksim Goryuk, PhD in Technics (Candidate of Technics Sciences), Senior Researcher, Physical and technological Institute of metals and alloys academy of sciences of Ukraine, Kyiv, Ukraine
Abstract
The analysis of the basic parameters of the dosage of molten iron in metal forms using the magnetodynamic installation MDN-6CH. A schematic diagram has been developed for controlling the electromagnetic systems of the unit. The technology of dosing and pouring metal into the chill mold has been developed in the manufacture of cast iron balls with a diameter of 40 and 120 mm.
At the optimal casting temperature, the electrical parameters of the inductor (voltage Ui, current Ii, power Ri) were in the range Ui = 250-300 V, Ii = 480-520 A, Ri = 140-160 kW. When reducing the mass of metal in the crucible MDN-6CH using a control scheme made switching inductor from a voltage of 300 V to 250 V. The power was reduced by 15-20 kW, and the temperature of the metal remained within the tolerance of the technology of metal casting.
Using the adopted dosing scheme, it became possible to cast metal at constant parameters of the electromagnetic system and the time of pouring. The technology of dispensing and pouring metal into the mold for the production of cast iron balls with a diameter of 40 and 120 mm was carried out at an inductor voltage of 300 V, and the electromagnet - 220 V. The initial level of metal on the drain socket was equal to 20 mm. The molding time of molds in the manufacture of balls with a diameter of 40 mm was 7.3 s, and balls with a diameter of 120 mm - 16.2 s. The operating time of the electromechanical actuator was set in the manufacture of balls with a diameter of 40 mm - 0.35 s, and balls with a diameter of 120 mm - 0.75s. The consumption of metal in the manufacture of balls with a diameter of 40 and 120 mm was in the range of 0.7-0.75 kg / s and 1.65-1.70 kg / s, respectively. The metal casting was carried out at temperatures of 1320-1340 ° C and 1360-1380 ° C. The dosage accuracy was determined by weighing the metal of the poured balls and the molding system of the mold.
Mathematical processing of the results of the dosing showed that in the manufacture of balls with a diameter of 40 mm at a temperature of 1320 °C the error of dosing is 10-11%. With increasing iron temperature, the dosage error decreases and at a metal temperature of 1370 °C is 5-6%. In the manufacture of balls with a diameter of 120 mm at a temperature of iron 1330, the dosage error is 7-8%, and at a temperature of 1360 ° C - 3-4%.
The study of the characteristics of the casting and dosing process of cast iron in the chill mold allowed us to develop the technology of casting cast iron melts, which provided the required metering accuracy and high productivity of the conveyor production of grinding bodies.
Keywords
cast iron, melt, magnetodynamic installation, chill mold, control circuit
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References
1. Efimov, V.А., Anisovich, G.А., Babich, V.N. et al. (1991). Special'nye sposoby litja [Special casting methods]. Moscow: Mashinostroenie [in Russian].
2. MGD v litejnom proizvodstve i metallurgii. [Magnetic hydrodynamics in foundry and metallurgy]. Sbornik nauchnyh trudov. (1984). К.: АN USSR [in Russian].
3. Dubodelov, V.I., Pogorskij, V.К., Dolzhikov, А.А. (1981). Intencifikaciya MGD-teplomassoperenosa v indukcionnyh kanal'nyh pechah [Intensification of MHD heat and mass transfer in induction channel furnaces]. Perm-Kiev: АN USSR [in Russian].
4. Krylov, Yu.A., Ruskol, V.I., Filatov, S.К. (1990). Avtomaticheskoe regulirovanie dozy v ustanovke s pogrugnym MGD-nasosom [Automatic dose control in a submersible MHD pump]. Litejnoe proizvodstvo – Foundry, Vol 12, 11-12. [in Russian].
5. Dubodelov, V.I., Pogorskij, V.К., Kropivnyj, V.M., Lomakin, V.M. (1999). Chislennoe issledovanie kinetiki zatverdevaniya melyushchih tel v metallicheskih formah s estestvennym vozdushnym ohlagdeniem [Numerical study of the solidification kinetics of grinding media in metallic forms with natural air cooling]. Zbіrnik naukovih prac' Kіrovgrads'kogo derzhavnogo tehnіchnogo unіversitetu – Collection of scientific works of Kirovgrad State Technical University, Vol. 4, 5-10 [in Russian].
6. Lomakin, V.M., Klymenko, V.V., Pukalov, V.V., Lomakin, A.V. (2016). Doslidgennya vplyvu kinetyky krystalizacii na vlastyvosti kokil'nyh vylyvkiv chavunnyh cyl'pebsiv [Investigation of the effect of crystallization kinetics on the properties of chill castings of cast iron grinding bodies]. Tekhnika v sil's'kohospodars'komu vyrobnytstvi, haluzeve mashynobuduvannia, avtomatyzatsiia: zb. nauk. pr. Kirovohr. nats. tekhn. un-tu. – Collection of Scientific Works of KNTU. Engineering in agricultural production, industrial engineering, automation, Vol. 29, 132-139 [in Ukrainian].
7. Lomakin, V.M., Klymenko, V.V., Pukalov, V.V., Kuzyk, О.V., Dubodelov, V.I., Goryuk, M.S. (2018). Doslidgennya procesu zatverdinnya ta prognozuvannya struktury lytyh chavunnyh molol'nyh til [Investigation of the process of solidification and prediction of the structure of cast iron grinding bodies]. Tekhnika v sil's'kohospodars'komu vyrobnytstvi, haluzeve mashynobuduvannia, avtomatyzatsiia: zb. nauk. pr. Kirovohr. nats. tekhn. un-tu. – Collection of Scientific Works of KNTU. Engineering in agricultural production, industrial engineering, automation, Vol. 31, 66-74. [in Ukrainian].
8. Dubodelov, V.I., Gonchar, B.S, Pogorskij, V.К. & Lomakin, V.M. (1999). Tekhnologicheskie osobennosti zalivki metallicheskih form pri izgotovlenii melyushchih tel iz chuguna [Technological features of pouring metal molds in the manufacture of grinding media from cast iron]. Processy litja – Casting processes, Vol 1, 41-47 [in Russian].
GOST Style Citations
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- МГД в литейном производстве и металлургии: Сб. науч. трудов. К.: Изд-во АН УССР. 1984. 111 с.
- Дубоделов В. И., Погорский В. К, Должиков А. А. Интенсификация МГД-тепломассопереноса в индукционных канальных печах. Пермь-Киев: изд-во АН УССР, 1981. С. 53-56.
- Крылов Ю. А., Рускол В. И., Филатов С. К. Автоматическое регулирование дозы в установке с погружньш МГД-насосом. Литейное производство. 1990. Вып. 12. С. 11-12.
- Дубоделов В. И., Погорский В. К., Кропивннй В. Н., Ломакин В. Н. Численное исследование кинетики затвердевания мелющих тел в металлических формах с естественним воздушннм охлаждением. Збірник наукових праць Кіровградського державного технічного університету. 1999. Вип. №4. С. 5-10.
- Ломакін В.М., Клименко В.В., Пукалов В.В., Ломакін А.В. Дослідження впливу кінетики кристалізації на властивості кокільних виливків чавунних цильпебсів. Техніка в сільськогосподарському виробництві, галузеве машинобудування, автоматизація: зб. наук. пр. Кіровогр. нац. техн. ун-ту. 2016. Вип. 29. С. 132-139.
- Ломакін В.М., Клименко В.В., Пукалов В.В., Кузик О.В., Дубодєлов В.І., Горюк М.С. Дослідження процесу затвердіння та прогнозування структури литих чавунних молольних тіл. Техніка в сільськогосподарському виробництві, галузеве машинобудування, автоматизація: зб. наук. пр. Кіровогр. нац. техн. ун-ту. 2018. Вип. 31. С. 66-74.
- Дубоделов В. И., Гончар Б. С, Погорский В. К., Ломакин В. Н. Технологические особенности заливки металлических форм при изготовлении мелющих тел из чугуна. Процессы литья. 1999. Вып. 1. С. 41-47.
Copyright (c) 2020 Viktor Lomakin, Viktor Pukalov, Viktor Dubodelov, Maksim Goryuk
Automation of Batch Casting of Cast Iron Melts in the Chill Mold in the Production of Castings of Machine Parts for the Mining Industry
About the Authors
Viktor Lomakin,Associate Professor, PhD in Technics (Candidate of Technics Sciences), Central Ukraіnian National Technical University, Kropyvnytskyi, Ukraine
Viktor Pukalov, Associate Professor, PhD in Technics (Candidate of Technics Sciences), Central Ukraіnian National Technical University, Kropyvnytskyi, Ukraine
Viktor Dubodelov, Professor, Doctor in Technics (Doctor of Technics Sciences), Physical and technological Institute of metals and alloys academy of sciences of Ukraine, Kyiv, Ukraine
Maksim Goryuk, PhD in Technics (Candidate of Technics Sciences), Senior Researcher, Physical and technological Institute of metals and alloys academy of sciences of Ukraine, Kyiv, Ukraine
Abstract
Keywords
Full Text:
PDFReferences
1. Efimov, V.А., Anisovich, G.А., Babich, V.N. et al. (1991). Special'nye sposoby litja [Special casting methods]. Moscow: Mashinostroenie [in Russian].
2. MGD v litejnom proizvodstve i metallurgii. [Magnetic hydrodynamics in foundry and metallurgy]. Sbornik nauchnyh trudov. (1984). К.: АN USSR [in Russian].
3. Dubodelov, V.I., Pogorskij, V.К., Dolzhikov, А.А. (1981). Intencifikaciya MGD-teplomassoperenosa v indukcionnyh kanal'nyh pechah [Intensification of MHD heat and mass transfer in induction channel furnaces]. Perm-Kiev: АN USSR [in Russian].
4. Krylov, Yu.A., Ruskol, V.I., Filatov, S.К. (1990). Avtomaticheskoe regulirovanie dozy v ustanovke s pogrugnym MGD-nasosom [Automatic dose control in a submersible MHD pump]. Litejnoe proizvodstvo – Foundry, Vol 12, 11-12. [in Russian].
5. Dubodelov, V.I., Pogorskij, V.К., Kropivnyj, V.M., Lomakin, V.M. (1999). Chislennoe issledovanie kinetiki zatverdevaniya melyushchih tel v metallicheskih formah s estestvennym vozdushnym ohlagdeniem [Numerical study of the solidification kinetics of grinding media in metallic forms with natural air cooling]. Zbіrnik naukovih prac' Kіrovgrads'kogo derzhavnogo tehnіchnogo unіversitetu – Collection of scientific works of Kirovgrad State Technical University, Vol. 4, 5-10 [in Russian].
6. Lomakin, V.M., Klymenko, V.V., Pukalov, V.V., Lomakin, A.V. (2016). Doslidgennya vplyvu kinetyky krystalizacii na vlastyvosti kokil'nyh vylyvkiv chavunnyh cyl'pebsiv [Investigation of the effect of crystallization kinetics on the properties of chill castings of cast iron grinding bodies]. Tekhnika v sil's'kohospodars'komu vyrobnytstvi, haluzeve mashynobuduvannia, avtomatyzatsiia: zb. nauk. pr. Kirovohr. nats. tekhn. un-tu. – Collection of Scientific Works of KNTU. Engineering in agricultural production, industrial engineering, automation, Vol. 29, 132-139 [in Ukrainian].
7. Lomakin, V.M., Klymenko, V.V., Pukalov, V.V., Kuzyk, О.V., Dubodelov, V.I., Goryuk, M.S. (2018). Doslidgennya procesu zatverdinnya ta prognozuvannya struktury lytyh chavunnyh molol'nyh til [Investigation of the process of solidification and prediction of the structure of cast iron grinding bodies]. Tekhnika v sil's'kohospodars'komu vyrobnytstvi, haluzeve mashynobuduvannia, avtomatyzatsiia: zb. nauk. pr. Kirovohr. nats. tekhn. un-tu. – Collection of Scientific Works of KNTU. Engineering in agricultural production, industrial engineering, automation, Vol. 31, 66-74. [in Ukrainian].
8. Dubodelov, V.I., Gonchar, B.S, Pogorskij, V.К. & Lomakin, V.M. (1999). Tekhnologicheskie osobennosti zalivki metallicheskih form pri izgotovlenii melyushchih tel iz chuguna [Technological features of pouring metal molds in the manufacture of grinding media from cast iron]. Processy litja – Casting processes, Vol 1, 41-47 [in Russian].
GOST Style Citations
- Ефимов В.А., Анисович Г.А., Бабич В.Н. и др. Под общ. ред. В.А. Ефимова. Специальные способы литья: Справочник. М.: Машиностроение, 1991. 436 с.
- МГД в литейном производстве и металлургии: Сб. науч. трудов. К.: Изд-во АН УССР. 1984. 111 с.
- Дубоделов В. И., Погорский В. К, Должиков А. А. Интенсификация МГД-тепломассопереноса в индукционных канальных печах. Пермь-Киев: изд-во АН УССР, 1981. С. 53-56.
- Крылов Ю. А., Рускол В. И., Филатов С. К. Автоматическое регулирование дозы в установке с погружньш МГД-насосом. Литейное производство. 1990. Вып. 12. С. 11-12.
- Дубоделов В. И., Погорский В. К., Кропивннй В. Н., Ломакин В. Н. Численное исследование кинетики затвердевания мелющих тел в металлических формах с естественним воздушннм охлаждением. Збірник наукових праць Кіровградського державного технічного університету. 1999. Вип. №4. С. 5-10.
- Ломакін В.М., Клименко В.В., Пукалов В.В., Ломакін А.В. Дослідження впливу кінетики кристалізації на властивості кокільних виливків чавунних цильпебсів. Техніка в сільськогосподарському виробництві, галузеве машинобудування, автоматизація: зб. наук. пр. Кіровогр. нац. техн. ун-ту. 2016. Вип. 29. С. 132-139.
- Ломакін В.М., Клименко В.В., Пукалов В.В., Кузик О.В., Дубодєлов В.І., Горюк М.С. Дослідження процесу затвердіння та прогнозування структури литих чавунних молольних тіл. Техніка в сільськогосподарському виробництві, галузеве машинобудування, автоматизація: зб. наук. пр. Кіровогр. нац. техн. ун-ту. 2018. Вип. 31. С. 66-74.
- Дубоделов В. И., Гончар Б. С, Погорский В. К., Ломакин В. Н. Технологические особенности заливки металлических форм при изготовлении мелющих тел из чугуна. Процессы литья. 1999. Вып. 1. С. 41-47.