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Technology of manufacturing hollow-bored specific-length work pieces from various cast irons by the method of wall molding in cycle-continuous casting mode
Summary
A crucially new casting process and equipment employed to realize it provide for obtaining coreless hollow-bore cylinder work pieces exhibiting the output rate of 100-240 castings/h. The technology ensures improved mechanical and performance properties of casting material.[br][/br][br][/br]Fig. 1 – The process plant for cycle-continuous casting.[br][/br]
Description
Fig. 2 - cycle-continuous dip-forming process: 1 - metal duct; 2 - connection nozzle; 3 - fixed molding unit; 4 - movable molding unit; 5 - casting[br][/br][br][/br]The developed method is based on the principle of ensuring proper conditions for directional solidification. Its essence is as shown on Figure 1, 2. Liquid metal is fed through a bottom gate and a connection nozzle into a water-cooled mold consisting of a fixed and a movable section. Feeding continues till the appropriate casting height is reached. Then metal feeding is suspended to provide for molding a work piece wall of appropriate thickness. After skin making up the casting body solidifies it is drawn up from the fixed mold and metal bath with the help of gripping tools. Simultaneously, a new portion of liquid metal equal to the volume of the previous casting is fed into the mold. The cycle is reproduced. Thus, the casting process is effected in a cycle-continuous mode. The molding procedure is accompanied by intensive radial heat removal and abundant feeding of the solidification front with liquid phase over the entire solidification period. This eliminates shrinkage and gas porosity, presence of non-metallic and cinder inclusions in the casting body and ensures a high-dispersion structure, improved density and hardness of work-pieces. Absence of any core provides for free shrink-off both during casting solidification period and its subsequent cooling following extraction from the molding form, which helps to avoid pull cracks and microfissures. The technology allows due control of the cooling process to obtain required structure. [br][/br]
Technology Type
Process
Technology Benefits
The developed technology helps save resources and energy since heat treatment employs only primary casting heat without any external power sources. Besides, it provides for a more effective use of waste materials resulting from casting process and mechanical treatment.
Technology Differentiation and Uniqueness
The technology ensures crucially new conditions for hollow-bore work pieces molding which presupposes directional solidification accompanied by intensive one-side radial heat removal and constant overheating of the metal bath at the solidification front.
Context in which technology was identified
the XIIIth International Congress and Exhibition "HIGH TECHNOLOGIES, INNNOVATIONS, INVESTMENTS"; Saint-Petersburg, March 11-14, 2008; the VIIIth Moscow International Salon of Innovations and Investments, Moscow, All-Russia Exhibition Centre, March 3-6, 2008; the 11th International Symposium "Technologies, Equipment, Quality", Minsk, May 13-16, 2008; St. Petersburg Technical Fair 10-12 March 2010, St. Petersburg Technical Fair on 12-14 March 2013.
Technological Keywords
Directional solidification, freezing-out, one-side heat removal, mold.
Development Stage
Currently in use/production
Specific Patent Information (Patent Number, Country, Patent Status)
Author's certificate, the USSR No 799241 as of 22.09.1980 , Author's certificate USSR No 1042237 as of 16.05.1983, License BY No 2343 as for 30.12.2005, License BY No 2544 as of 28.02.2006, License BY No 2943 as of 30.08.2006, License BY No 3165 as of 30.12.2006, License BY No 9756 as of 30.10.2007.[br][/br]
Range of Applications
Foundry operation - manufacturing work pieces for high-duty parts used in manufacturing engineering, metallurgy, automobile and tractor industry, construction and etc.
Classifier Used at the Enterprise Europe Network
Materials
Preferable Regions
Asia
Practical Experience
Technology introduced at UCH NPP "Tekhnolit" (Mogilev) and is used for research and production site SSI "ITM NAS of Belarus" to produce high-duty application parts of grey, high-strength and white cast iron having improved performance properties and operational resources: cylinder liners, piston and sealing rings, valve seats, punch stamps for pressers manufacturing cellular lime brick, braking cable machine disks for wire cable production, multi-purpose bushuings.
Environmental Impact
None.
Type of Collaboration Sought
R&D Contract
Terms&Restrictions
Transfer of information to third parties without previous agreement is not allowable.
Available Technical Assistance
Documentation
Personnel
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