Home/ Majors directory/Computer-integrated technologies of art and jewelry casting/Theoretical Foundations of Foundry
Theoretical Foundations of Foundry
Major: Computer-integrated technologies of art and jewelry casting
Code of subject: 6.136.03.O.026
Credits: 4.50
Department: Department of Materials Science and Engineering
Lecturer: Dr.Sc., Kulyk Volodymyr Volodymyrovych
Semester: 5 семестр
Mode of study: денна
Завдання: Formation of professional competencies:
? FC 1 - the ability to apply a systematic approach to solving metallurgical problems.
? FC 2 - critical understanding of scientific facts, concepts, theories, principles and methods necessary for professional activity in the field of metallurgy.
? FC 5 - the ability to apply scientific and engineering methods, as well as computer software to solve typical and complex tasks of foundry production, including under conditions of uncertainty.
? FC 6 - the ability to define and investigate a problem in the field of computer modeling and development of artistic and jewelry casting technologies, as well as to identify limitations, in particular those related to issues of sustainable development, environmental protection, health and safety and risk assessments.
? FC 9 - the ability to identify, classify and describe the effectiveness of systems, components and processes in metallurgy based on the use of analytical and modeling methods.
? FC 11 - the ability to implement concepts of lean production and general principles of reducing production costs in metallurgy, as well as to introduce resource-saving technologies that allow accumulating resources aimed at achieving goals in all areas of activity of metallurgical and foundry enterprises.
? FC 12 - awareness of the requirements for activities in the field of foundry production, determined by the need to ensure sustainable development.
? FC 13 - the ability to solve typical engineering tasks of foundry production, in particular with the use of modern computer modeling tools.
? FC 14 - awareness of the characteristics of specific materials, equipment, processes and products of foundry production.
? FC 15 - the ability to apply the best world practices, standards of activity in metallurgy with the specialization of computer-integrated technologies of artistic and jewelry casting.
? FC 16 - the ability to manage complex actions or projects in foundry production to ensure the achievement of the set goal, taking into account all aspects of the problem being solved, including those related to production, operation, maintenance and disposal.
? FCS 1.1 - the ability to rationally choose materials, typical technological processes, equipment and tools for the manufacture of metal products, including using modern CAD/CAM/CAE systems, in order to ensure the specified properties, required quality indicators, minimum cost and impact on the environment with high technical and economic indicators of production.
? FCS 1.2 - awareness of the main stages of designing the technology of the casting mold, the properties of materials for the manufacture of model devices, the properties of molding and core materials, the ability to calculate sprue systems for the manufacture of castings from various alloys, to develop the necessary technological documentation taking into account the type of production.
? FCS 1.5 – the ability to calculate the number of foundry equipment and its layout in the production areas of the foundry, determine the operating modes of the foundry, its ventilation and lighting systems, calculate the amount of casting material according to the technology for manufacturing a given number of castings, propose basic measures for fire safety and labor protection.
? FCS 2.6 – the ability to apply appropriate quantitative mathematical, scientific and technical methods and computer software to solve typical engineering problems in the field of foundry production, based on a systems approach to solve qualitative and quantitative problems in real production conditions.
? FCS 2.7 – the ability to use information on the technology of material and product production, with the help of certain provisions and scientific and technical literature, to prepare source data for the selection and justification of scientific and technical and organizational solutions in the field of foundry production.
Learning outcomes: ZN 2 - knowledge and understanding of the engineering sciences that underlie the specialization, at the level necessary to achieve other program outcomes, including sufficient awareness of their latest achievements.
ZN 3 - advanced knowledge in the field of metallurgy and, in particular, computer-integrated technologies of artistic and jewelry casting.
ZN 5 - understanding of the characteristics of the materials used, equipment and tools, engineering technologies and processes, as well as their limitations in foundry production.
ZN 8 - understanding of the best global practices and standards of activity and the skills to apply them in the metallurgical industry of Ukraine.
UM 1 - the ability to identify, formulate and solve typical and complex and unpredictable engineering tasks and problems of foundry production, which includes collecting and interpreting information (data), selecting and using appropriate equipment, tools and methods, applying innovative approaches and specialized software.
UM 4 - the ability to develop, design and model foundry processes and systems that meet the established requirements, assuming awareness of non-technical (society, health and safety, environment, economy) aspects, to select and apply adequate design methodologies, including computer-aided design tools.
UM 5 - the ability to select and use management systems and organization of foundry production in the field of artistic and jewelry casting.
UM 15 - the ability to apply the concepts of lean production and general principles of reducing production costs in metallurgy.
Required prior and related subjects: Higher Mathematics
Physics
Descriptive Geometry, Engineering and Computer Graphics
Materials Science and Technology of Structural Materials
Theory of Heat and Mass Transfer
Theoretical Fundamentals of Forming
Foundry Mold Technology
Summary of the subject: The discipline studies the basic physicochemical laws of crystallization, formation of the structure and properties of metals and alloys; casting properties of alloys and methods for their determination; equipment used for smelting casting alloys; purpose and scope of application of various methods for obtaining cast blanks depending on the casting properties of alloys; requirements for the manufacturability of cast parts; causes of various types of defects during casting and methods for their elimination;
The discipline teaches how to select technological processes for obtaining castings taking into account the properties of the workpiece material; develop optimal technological processes for manufacturing cast blanks without casting defects with a given structure and set of properties; control the structure during solidification and cooling to obtain given properties of casting alloys; reasonably choose casting alloys, casting technologies and subsequent processing of castings to ensure low material consumption, reliable and long-term operation of machine parts in operating conditions.
Опис: Foundry production in mechanical engineering. Development of foundry production in Ukraine.
Classification of castings and requirements for them. Structural elements of the casting and the sprue-feeding system.
Classification and properties of foundry alloys
Classification of methods of manufacturing castings (casting in disposable and semi-solid molds, manufacturing of castings in metal molds, by pressure casting, using melted and fired models, in shell molds, stamping of liquid metal, electroslag casting; centrifugal casting of blanks, freezing casting, continuous and semi-continuous casting)
Composition and properties of charge materials
Melting and evaporation of metals.
Foundry properties of alloys (fluidity, filling of the mold, interaction with gases, non-metallic inclusions).
Processing of alloys in the liquid state (refining, fluxing, alloying, modification).
Elements of sprue systems. Types of sprue systems. Features of filling sprue channels. Regulation of the operation of sprues (feeding castings during shrinkage, calculation of sprues).
Basic requirements for mold and core mixtures. General concept of molding and core materials. Molding and core mixtures
Basic properties of materials. Atomic-crystalline structure of metals and alloys. Defects of the crystalline structure of metals. Thermodynamic foundations of phase transformations of metals. Crystallization and structure of a metal ingot. Regulation of crystallization processes and types of crystal structures in castings
Processes of structure formation in castings. Crystallization of alloys that form a solid solution (Dendrite crystallization of alloys, Formation of equiaxed crystals, Eutectic crystallization of alloys). Non-equilibrium crystallization and development of liquation. Types of liquation.
Shrinkage processes during solidification of castings. Development of stresses and cracks in castings. Casting defects and cause-and-effect relationships with casting processes. (Classification of defects. Burn-in. Surface tension of the mold and shrinkage. Sieve porosity.)
Theory of alloys. Phase diagrams of alloys. Physical and mechanical properties of alloys in the equilibrium state. Relationship between the type of phase diagram, composition and properties of alloys. Iron-cementite phase diagram.
Assessment methods and criteria: 1. Interview and admission to practical work.
2. Defense of practical work, including those completed on individual assignments.
3. Examination control with written and oral components.
Критерії оцінювання результатів навчання: • written reports from practical work, oral questioning (40%);
• final control (60%, exam): written-oral form.
Recommended books: Basic
1. Могилатенко В. Г. Теоретичні основи ливарного виробництва: навч. посіб. для студ. спец. "Обладнання ливарного виробництва" і "Ливарне виробництво чорних та кольорових металів" / В. Г. Могилатенко [та ін.] ; Нац. техн. ун-т "Харк. політехн. ін-т". – Х. : НТУ "ХПІ", 2011. – 287 с.
2. Лисенко Т. В. Теоретичні основи формування виливків : навч. посіб. для студентів вищ. техн. навч. закл., які навчаються за спец. "Ливарне виробництво чорних та кольорових металів і сплавів" та "Обладнання та технології ливарного виробництва" / Т. В. Лисенко [та ін.]; Нац. техн. ун-т "Харків. політехн. ін-т". – Харків : НТУ "ХПІ", 2014. – 191 с.
3. Дан Л. О. Ливарне виробництво: навчальний посібник для студентів металургійних спеціальностей / Л. О. Дан, Л. О. Трофімова ; М-во освіти і науки України, ПДТУ. Каф. технології і комп`ютерізації ливарного виробництва. – Маріуполь : ПДТУ, 2013. – 207 с.
4. Дусанюк Ж. П. Проектування та виробництво заготовок деталей машин. Литі заготовки: навчальний посібник / Ж. П. Дусанюк, О. П. Шиліна, С. В. Репінський, С. В. Дусанюк. – Вінниця: ВНТУ, 2009. – 199 с.
Auxiliary
1. Sahoo M. Principles of Metal Casting / M. Sahoo, S. Sahu. – Third Edition 3rd Edition, MsGraw-Hill Education, 2014. –795 p.
2. Srinivasan M. Science and Technology of Casting Processes / M. Srinivasan; InTech, 2012. – 350 p.
3. Campbell F.C. Elements metallurgy and engineering alloys / F.C. Campbell. – ASM International, 2008. – 645 р.
4. Chakrabarti A.K. Сasting technology and cast alloys / A.K. Chakrabarti. – PHI Learning Pvt. Ltd., 2005. – 288p.
5. Campbell J. Complete Casting Handbook. 2nd Edition: Metal Casting Processes, Metallurgy, Techniques and Design. Elsevier / J. Campbell: Butterworth-Heinemann, 2015. – 1054p.
Information resources
1. http://www.sciencedirect.com/science/book/9780750642842