Mathematical model of heating system before the melting of the metal suspension upper half in the manufacture of turbine blades GTE

The article presents the developed mathematical model of heating system before the upper half of the metal suspension melting during the technological process of manufacturing the turbine blades in a discrete-continuous casting plant. The relevance of this research is connected with the lack of reliable mathematical model that can predict the distribution of temperature fields and heat flows inside the plant, which have a direct impact on the quality of formed macro - and microstructure in the castings of turbine blades. The currently existing methods of indirect indicators’ estimation carry significant errors in the selection of optimal technological modes of the blade casting process. The developed model makes it possible to predict more accurate the distribution of temperature fields and heat fluxes in the corresponding zones of the casting plant. Thanks to this, it is possible to predict with maximum accuracy the production of blades with a given internal structure, as well as to estimate the amount of volumetric shrinkage and deformation of the casting. The developed mathematical model in production conditions will make it possible to predict casting defects in the form of captivity and failure, reduce labor capacity and increase the productivity of the blade casting process.

A System Modelling Approach Optimization Process and Machine Utilization In Casting Plant Using Lean Manufacturing Simulation Model

Perbaikan berkelanjutan, reduksi dan eliminasi waste dalam proses bisnis menjadi salah satu aspek yang dilakukan agar dapat terus memiliki daya saing yang sustainable. PT. X saat ini sedang dalam proses melakukan transformasi, reduksi dan eliminasi NVA serta perbaikan berkelanjutan di sisi proses guna meningkatkan daya saing yang sustainable. penelitian ini bertujuan dalam menganalisis dan mengajukan formulasi perbaikan proses menggunakan metode kerangka kerja pemodelan sistem dan simulasi. Temuan dari penelitian diketahui bahwa peningkatan Utilisasi Dies rata-rata 82,82 % relative meningkat 36% dibanding simulasi sebelumnya (52,9%); dengan rata-rata output 21,04 pcs/jam relative meningkat 42% dibanding simulasi sebelumnya (12,9 pcs/jam), hal ini dengan melakukan improvement proses semi auto dalam proses eject produk yang sekaligus berdampak dalam pengurangan manpower, serta mereduksi loss time akibat lama proses pendinginan dengan sistem heat transfer conveyor system

MODELING OF ROLL CASTING AND ROLLING OF METALS

В данной работе представлены результаты изучения процесса валковой разливки с применением методов физического и математического моделирования. Показано, что стабильность процесса валковой разливки-прокатки металлов зависит от таких технологических параметров, как температура перегрева, скорость разливки и уровень расплава в межвалковом пространстве. Для использованных в процессе исследования сплавов получены зависимости оптимальной скорости разливки-прокатки от толщины полосы, угла мениска металла, радиуса валков и температуры перегрева расплавов.Экспериментальная составляющая данных исследований, выполненная в лабораторных условиях на установке валковой разливки металлов, подтвердила адекватность и высокое качество расчетных режимов разливки для всех изучаемых сплавов. Полученная для описания изучаемых процессов валковой разливки металлов математическая модель показала высокую корреляцию теоретических и экспериментальных данных, что свидетельствует о корректности данной модели. This paper presents the results of studying the roll casting process using physical and mathematical modeling methods. It is shown that the stability of the roll casting-rolling process of metals is provided by such technological parameters as the overheating temperature, the casting speed and the melt level in the inter-roll space. For the alloys used in the study, the dependences of the optimal casting-rolling speed on such technological indicators as the thickness of the strip, the angle of the metal meniscus, the radius of the rolls and the temperature of overheating of the melts were obtained. The experimental component of these studies, performed under laboratory conditions at the roll casting plant of metals, confirmed the adequacy and high quality of the calculated casting modes for all the studied alloys. The mathematical model obtained to describe the studied processes of roll casting of metals showed a high correlation of theoretical and experimental data.

Exergy analysis and efficiency evaluation for an aluminium melting furnace in a die casting plant

An aluminium melting furnace efficiency in a die casting plant was investigated using energy and exergy methods. Energy efficiency and exergy efficiency values were evaluated for the natural gas-fired furnace, and the efficiency improvement was analyzed before and after two new regenerative burners were installed on the furnace. The research analyzed and compared the environmental impacts attributable to the melting furnace before and after the burner upgrading project, and also provided a financial analysis of the capital investment of the upgrading project. The study shows that the exergy method can be used beneficially to analyze the furnace efficiency and that exergy efficiency is a more practical measure in reality. Thus, it is believed that further applications of exergy methods are desirable to a wider range of industrial and engineering applications. From the results of comparisons, the study shows that the regenerative burner technology and stage-combustion technique can improve combustion performance, reduce fuel (natural gas) consumption and lower NOx and Co2 emissions. Adopting the regenerative burner and stage-combustion technique will be beneficial to the die casting plant on energy saving and cost reduction. Recommendations are also made for further efficiency improvements.

Exergy analysis and efficiency evaluation for an aluminium melting furnace in a die casting plant

An aluminium melting furnace efficiency in a die casting plant was investigated using energy and exergy methods. Energy efficiency and exergy efficiency values were evaluated for the natural gas-fired furnace, and the efficiency improvement was analyzed before and after two new regenerative burners were installed on the furnace. The research analyzed and compared the environmental impacts attributable to the melting furnace before and after the burner upgrading project, and also provided a financial analysis of the capital investment of the upgrading project. The study shows that the exergy method can be used beneficially to analyze the furnace efficiency and that exergy efficiency is a more practical measure in reality. Thus, it is believed that further applications of exergy methods are desirable to a wider range of industrial and engineering applications. From the results of comparisons, the study shows that the regenerative burner technology and stage-combustion technique can improve combustion performance, reduce fuel (natural gas) consumption and lower NOx and Co2 emissions. Adopting the regenerative burner and stage-combustion technique will be beneficial to the die casting plant on energy saving and cost reduction. Recommendations are also made for further efficiency improvements.

KASLI ART CASTING TECHNOLOGY

The Kasli art casting technology is characterized by its uniqueness; the products are distinguished by precision of execution and uniqueness of style. The Kasli Casting Plant occupies a well-deserved first place in Russia in terms of quality and quantity of products. The object of the research is the features of each of the stages when creating of Kasli castings, as well as the distinctive features of the art casting technology. As a result of the study, the conclusion was formulated that the historical role of Kasli art casting is its influence on the decorative and applied art of Russia. According to the authors, the Kasli plant influenced the further production of castings, producing high-quality products with careful study of details, ensuring a high level of quality for the foundry workers