Casting Equipment Engineering Guide

• Autore: Nath Jagan
• Pubblicazione: Materials Park : , : A S M International, , 2023; ©2023
• Edizione: 1st ed.
• Descrizione fisica: 1 online resource (226 pages)
• Soggetto topico: Aluminum castings; Iron founding; Metal castings; Steel castings
• Nota di contenuto: Intro -- Contents -- Preface -- About the Author -- Casting Manufacturing Layout-Principles and Guidelines -- 1.1 -- 1.1.1 -- 1.1.2 -- 1.1.3 -- 1.1.4 -- 1.1.4.1 -- 1.2 -- 1.2.1 -- 1.2.2 -- 1.2.3 -- 1.3 -- Appendix -- Sand and Metal Charge Storage and Handling -- 2.1 Metallic Charge Materials -- 2.1.1 Large Bulk Amounts -- 2.1.2 Smaller Packages -- 2.2 Raw Material Handling -- 2.2.1 Metallic Charge Materials - Large Bulk Amounts -- 2.2.2 Nonmetallic Materials - Large Amounts of Silica and Olivine Sands -- 2.2.3 Nonmetallic Materials - Coke and Limestone -- 2.2.4 Nonmetallic Materials - Bentonite, Sea Coal, and Dextrin -- 2.2.5 Nonmetallic Materials - Resin Binders, Sodium Silicate, and Mold Coatings -- 2.3 Scrap-Breaking Equipment -- 2.4 Sand Drying, Cooling, and Storage -- 2.4.1 Types of Sand Dryers -- 2.4.1.1 Advantages of Drum or Rotary Dryers -- 2.4.1.2 Advantages of fluidized bed dryers -- 2.4.2 Drum or Rotary Dryers and Coolers -- 2.4.3 Fluidized Bed Dryers and Coolers -- 2.5 Handling and Dosing of Bentonite and Sea Coal -- Sand Conditioning Equipment -- 3.1 Sand Dosing into the Muller -- 3.1.1 Variable Feed Belt Speed -- 3.1.1.1 Calibration -- 3.1.2 Dosing Hopper with Load Cell -- 3.2 Sand Muller Types and Features -- 3.2.1 Vertical Roller-Type Muller -- 3.2.2 Horizontal Roller-Type Muller -- 3.2.3 Duplex Muller -- 3.2.4 DISAMATIC Sand Mixer -- 3.2.5 Continuous Screw-Type Muller -- 3.3 Automated Sand Conditioning Control -- 3.3.1 Time-Controlled and Energy-Controlled Mulling -- 3.4 Core Sand Mixers -- 3.5 Sand Conveyors and Bucket Elevators -- 3.5.1 Sand Conveyors -- 3.5.2 Bucket Elevators -- 3.6 Sand Aerators -- 3.6.1 Types of Aerators -- 3.6.1.1 Belt-Type Aerator -- 3.6.1.2 Pin Bushing-Type Aerator -- 3.7 Mold Conveyors-Types and Lengths for Cooling -- 3.7.1 Mold Conveyors -- 3.7.1.1 Roller Conveyors. ; 3.7.1.2 Guide Rail System for Mold Movement -- 3.7.1.3 Multilevel Mold Conveyors -- 3.7.1.4 Walking Beam Mold Conveyor - Precision Mold Conveyor -- 3.7.1.5 Sliding Mold Conveyor - Automatic Mold Conveyor -- 3.7.1.6 -- 3.7.2 Engineering for Cooling Time -- 3.7.2.1 Example Calculation of Conveyor Length for Gray Iron Foundries -- 3.7.2.2 Conveyor Length for Ductile Iron Castings -- 3.7.2.3 Conveyor Length for Steel Castings -- 3.7.3 Flexibility in Conveyor Design -- 3.7.4 Extended Cooling Times -- 3.8 Shakeout Units and Features -- 3.8.1 Basic Brute and Variable Drives -- 3.8.2 Two-Mass High-Frequency Type (Ref 16, 17) -- 3.8.3 Vibratory Drum-Type -- 3.8.4 Rotary Drum-Type -- 3.8.5 Hydroblasting -- 3.8.6 Summary -- 3.9 Magnetic Separators -- 3.9.1 Magnetic Drum -- 3.9.2 Magnetic Pulley Segment -- 3.9.3 Belt-Type Magnetic Separator -- 3.10 Lump Breakers and Core Crushers -- 3.10.1 Over-Screen-Type Lump Breakers -- 3.10.2 Roller-Type Lump Breakers -- 3.10.3 Rotary-Type Lump Breakers -- 3.10.4 Attrition Mills -- 3.10.5 Hybrid Units -- 3.11 Screens -- 3.11.1 Hexagonal screens -- 3.11.2 Rotary Drums -- 3.11.3 Vibratory screens -- 3.12 Sand Coolers -- 3.12.1 Sand Cooling Processes -- 3.12.2 Sand Cooling Types -- 3.12.3 Stages of Sand Cooling -- 3.12.4 Heat Exchangers for Sand Cooling -- 3.12.5 Sand Cooling in Mullers and Mixers -- 3.13 Sand Reclamation Systems -- 3.13.1 Impact of Reclamation -- 3.13.2 Dry Reclamation -- 3.13.3 Wet Reclamation -- 3.13.4 Thermal reclamation -- 3.14 Prepared Sand Hoppers and Automated Level Control -- 3.14.1 Bin or Hopper Shapes for Reduced Bridging -- 3.14.2 Bin or Hopper Linings or Coatings -- 3.14.3 Design for Vibrators to Remove Jamming -- 3.14.4 Sand Level Measurement in Hoppers -- Molding Flasks and Molding Machines -- 4.1 Molding Flask Designs -- 4.1.1 Materials for Flasks -- 4.1.1.1 Rigidity -- 4.1.1.2 Strength. ; 4.1.1.3 Accuracy -- Outline placeholder -- 4.1.1.3.1 Alignment Accuracy -- 4.1.1.3.2 Perpendicularity of Guide-Pin Axes and Mating Surfaces -- 4.2 Mold Pallets -- 4.3 Molding Machines -- 4.3.1 Comparison of Tight Flask Molding and Flaskless Molding -- 4.3.2 Pneumatically and Hydraulically Compacted Molding Machines -- 4.3.3 Multistation Machines -- 4.3.4 Molding Machine Features Enhancements -- 4.3.4.1 Hopper Filling Improvements -- Outline placeholder -- 4.3.4.1.1 Gravity Fill -- 4.3.4.1.2 Blow Fill -- 4.3.4.1.3 Aeration Fill -- 4.3.4.1.4 Airflow -- 4.3.4.2 Squeeze Pressure Balance Control -- 4.3.4.3 Mold Height Control - Vertically Parted Molds -- 4.3.4.4 Pattern Plate Heater -- 4.3.4.5 No-spill Sand-Horizontal Parting Plane -- 4.3.4.6 Leveling Frame Pattern Draw -- 4.3.4.7 Multiram Squeeze -- 4.3.4.8 Light Curtain Safety Feature -- 4.3.4.9 Automated Pattern Plate Change -- 4.3.4.10 Molding Machine Controls and Diagnostics -- 4.4 Flaskless Molds -- 4.4.1 Horizontally Parted Flaskless Molding -- 4.4.2 Flask and Flaskless Flexible Molding Machines -- 4.4.3 Vertical Molded and Horizontally Cast Molding Machine -- 4.4.4 Vertically Parted Molding Machines -- 4.4.4.1 Machine Sizes and Outputs -- 4.5 No-Bake Molding Lines -- 4.5.1 Rollover and Draw Machines -- 4.5.2 Mold Manipulators -- 4.5.3 Flow Coating and Drying -- 4.5.4 No-Bake Core-mold Assembly -- 4.5.5 Mold Clamping and Weight Loading -- 4.5.5.1 Mold Lifting Force Computation -- 4.5.5.2 ``C´´ Clamps for Mold Clamping -- 4.5.5.3 Dovetail Clamps for the Flasks -- 4.5.5.4 Automated Mold Weighting Systems -- Outline placeholder -- 4.5.5.4.1 Automated Mold Loading Conveyor -- 4.5.5.4.2 Automated Pick-and-Place Units -- 4.5.6 Automated Core-Setting Systems -- 4.6 Core-Making Equipment -- 4.6.1 Cold Box Core Machines -- 4.6.2 Shell Core Machines -- 4.6.3 3D Printed Cores -- Casting Cleaning Operations. ; 5.1 Casting Cleaning Operation Sequence -- 5.2 Casting Cleaning Options-Shot Blasting -- 5.2.1 Impeller Heads -- 5.2.2 Shot Blasting Machine Types and Suitability -- 5.2.2.1 Tumble Blasters -- Outline placeholder -- 5.2.2.1.1 Drum-Type Tumble Blasters -- 5.2.2.1.2 Barrel-Type Tumble Blasters -- 5.2.2.1.3 Continuous Barrel-Type Tumble Shot Blaster -- 5.2.2.2 Table Shot Blasters -- Outline placeholder -- 5.2.2.2.1 Swing Table Blasters -- 5.2.2.2.2 Twin Table Blasters -- 5.2.2.3 Cabinet-Type Blasters -- Outline placeholder -- 5.2.2.3.1 Dual Chamber Spinner Blasters -- 5.2.2.3.2 Monorail Conveyor Cabinet Shot Blasters -- 5.2.3 Safety Features in Shot Blasting Machines -- 5.3 Decoring, or Removal of Cores from Castings -- 5.3.1 Decoring Machines -- 5.3.2 Inspection Instrumentation for Core Remnants Checking -- 5.4 Degating, or Removal of Runners, Gates, and Feeders -- 5.4.1 Removal of Runners and Gates from Gray and White Iron Castings -- 5.4.2 Removal of Runners and Feeders from Ductile Iron Castings -- 5.4.3 Removal of Runners and Feeders from Steel Castings -- 5.5 Flash Removal and Automation -- 5.5.1 Grinding Machine Types and Applications -- 5.5.2 Automated Grinders -- 5.5.2.1 Computer Numerically Controlled Machine Grinding -- 5.5.2.2 Robotic Grinding -- 5.5.3 Guidelines for Grinding Wheel Selection -- 5.6 Heat Treatment -- 5.6.1 Stress-Relieving of Cast and Ductile Iron Castings -- 5.6.2 Annealing of Gray Iron Castings -- 5.6.3 Annealing and Normalizing of Ductile Iron Castings -- 5.6.4 Heat Treatment of Steel Castings -- 5.6.4.1 Austenitizing -- 5.6.4.2 Normalizing -- 5.6.4.3 Quench Hardening -- 5.6.4.4 Tempering -- 5.6.4.5 Annealing or Full Annealing -- 5.7 Product Quality Control -- 5.7.1 Gray Iron Castings -- 5.7.2 Ductile Iron Castings -- 5.7.3 Steel Castings -- Iron and Steel Melting Furnaces -- 6.1 Furnace Types and Applications. ; 6.2 Cupolas-Types, Advantages, and Applications -- 6.2.1 Cold-Blast Cupolas -- 6.2.2 Hot-Blast Cupolas -- 6.2.2.1 Recuperative Hot Blast Units -- 6.2.2.2. Preheated Air Blast Units -- 6.2.3 Cupola Classification According to the Lining -- 6.2.4 Continuous Operation of the Front-Slagging Cupola -- 6.2.5 Cupolas with a Forehearth -- 6.2.6 Cupola with a Holding Furnace or a Holder -- 6.2.7 Special Cupolas -- 6.2.7.1 Divided-Blast Cupolas -- 6.2.7.2 Oxygen-Enriched Cupolas -- 6.2.7.3 Cokeless Gas-fired Cupolas -- 6.2.7.4 Plasma-Fired Cupolas -- 6.2.8 Charging Systems Mechanization -- 6.2.9 Charge Height Monitoring Systems -- 6.2.9.1 Contact Height Monitoring -- 6.2.9.2 Noncontact Height Monitoring -- 6.3 Induction Furnace-Types and Applications -- 6.3.1 Coreless Induction Furnaces -- 6.3.1.1 Impact of Power Supply Frequency -- 6.3.1.2 Frequency and Furnace Size -- 6.3.1.3 Frequency and Melting Time -- 6.3.1.4 Influence of Furnace Size -- 6.3.1.5 Rate of Bath Temperature Rise -- 6.3.1.6 Power and Furnace Size -- 6.3.1.7 Holding Power -- 6.3.2 Channel-Type Holding Furnaces-Cast Irons -- 6.3.2.1 Channel Furnace Operation -- 6.3.3 Additional Furnace Features -- 6.3.3.1 Engineering Induction Furnaces for Emergency -- 6.3.3.2 Relining Time Reduction -- 6.3.3.3 Mechanized Charging Systems -- 6.3.3.4 Furnace Design for Easier Deslagging -- 6.3.3.5 Charge Preheating -- 6.3.3.6 Emission Control -- 6.4 Arc Furnace Features and Applications -- 6.4.1 Construction Features -- 6.4.2 Bath Agitation Improvement -- 6.5 Cost and Other Considerations in Furnace Selection -- 6.5.1 Costs -- 6.5.2 Metallurgical Factors -- 6.5.3 Environmental Factors -- 6.5.4 Power Requirements and Grid Power Fluctuations -- 6.5.5 Size Factor -- 6.5.6 Operator Skill Level -- 6.5.7 Alternative Furnace Options -- 6.6 Automatic Pouring Units -- 6.6.1 Pouring Units for Cast Irons. ; 6.6.2 Low-Pressure Pouring Units for Steel.
• Sommario/riassunto: Casting Equipment Engineering Guide is a comprehensive resource for the preparation and production of iron, steel, and aluminum castings, addressing the entire line of equipment involved. The publication covers various aspects such as sand and metal storage and handling, sand preparation, retrieval, and conditioning, flask design options, melting and metal handling, sand molding, core making equipment, and material movement through various manufacturing processes. It also provides guidelines for the selection and positioning of equipment for optimal productivity and cost-effectiveness. The author aims to assist those involved in casting manufacturing engineering, particularly those engaged in new equipment purchases, expansions, modifications, and automation of machinery. The book is also highly useful for casting buyers and purchasing managers.
• Titolo autorizzato: Casting Equipment Engineering Guide
• ISBN: 9781627084475; 1627084479; 9781523157884; 1523157887; 9781627084468; 1627084460
• Formato: Materiale a stampa
• Livello bibliografico: Monografia
• Lingua di pubblicazione: Inglese
• Record Nr.: 9911007163803321
• Lo trovi qui: Univ. Federico II