Casting Machine Research Articles

Restoration of continuous casting machine mold copper plates made of Cr–Zr bronze using multi-pass friction stir lap welding

An innovative technology has been developed and implemented for the restoration and manufacturing of new mold copper plates for continuous casting machines (CCMs) using wear-resistant composite coatings. These copper plates significantly surpass the service life of imported copper plates featuring galvanic coatings, sometimes by up to 20 times. However, the pressing challenge of restoring the copper plates of molds once they have reached the minimum permissible thickness remains unresolved. This study aimed to explore the feasibility of restoring a plate composed of precipitation-hardening Cr–Zr bronze with the same material by employing friction stir lap welding (FSLW). The objectives were to examine the structure, quality, and hardness of the welded joint, alongside investigating the impact of heat treatment (quenching and aging). By utilizing multi-pass FSLW method with a rotating tool crafted from a heat-resistant alloy and overlapping (partially overlapping) successive passes, a welded joint with a thickness of ~5 mm was achieved, devoid of critical continuity flaws (cracks or voids). Within the bronze layer restored through FSW, a softening effect ranging from 85–105 HV1 was observed compared to the initial hardness of the bronze in its hardened and aged state while in service (116–126 HV1). This is attributed to recrystallization and overaging, specifically the coarsening of chromium particles within the Cr–Zr bronze due to the heating of the weld nugget (stir zone) to 600–700 °C. The observed softening effect during FSW can be effectively rectified through heat treatment involving dissolution of the hardening phases followed by aging, resulting in a hardness increase to approximately 120–150 HV1. The process of restoring copper plates to their original thickness via the progressive and environmentally friendly FSW method, followed be the subsequent application of wear-resistant composite coatings, presents the opportunity for an almost infinite operational cycle of molds. This advancement could potentially eradicate the necessity for Russia to rely on importing such molds copper plates.

Optimization of Process Parameters for Machining of Steel Molds used for Aluminum Casting in Wheel Industry

The wheel industry, employing low-pressure casting techniques for producing lightweight alloy wheels, operates within a highly competitive manufacturing environment with significant production volumes. To fabricate essential mold core components for the aluminum wheel casting process, hot work tool steel alloys are selected for their exceptional durability and resistance to wear, fatigue, distortion, and high-temperature plastic deformation. Efficient machining operations for these steel molds require identifying optimal parameter combinations to minimize tool wear, surface roughness, and energy consumption while maximizing material removal rates. This study focuses on determining such parameters, utilizing DIN 1.2367 steel, to enhance manufacturing efficiency and meet industry requirements. The effects of machining parameters such as cutting speed, depth of cut, and number of inserts were investigated using the design of experiments. Depth of cut was determined as the most influential factor on tool wear, revealing the optimum parameter as 0.4 mm, followed by cutting speed. Notably, the number of inserts exhibits minimal direct impact but interacts significantly with the depth of cut, influencing wear patterns. This research contributes to sustainable machining practices by enhancing mold core manufacturing efficiency, prolonging tool life, and reducing tool wear. Such advancements are vital for the long-term competitiveness and environmental stewardship of the wheel industry.

The effect of phosphorus content in copper alloys used for crystallisers of continuous casting machines

One of the key elements defining the technical level and operational capabilities of continuous casting machines (CCM) is the complex of physico-mechanical properties of copper or copper alloys used in its production. The paper provides a comprehensive assessment of the possibility of obtaining high-quality copper plates for CCBC crystallizers based on domestic technologies and equipment using refined copper. Special attention was paid to the need to optimize the chemical composition of the copper alloy within a narrower range of chemical element values. The analysis of the research shows that currently used copper alloys for CCM crystallizer manufacturing have a wide range of fluctuations in the main operational properties, namely thermal conductivity (260-390 W/(m·K)) and solidification temperature (250-700 °C). However, most of the alloys used have narrower fluctuation limits for acceptable values, constituting 340-390 W/(m·K) for thermal conductivity and 300-370 °C for solidification temperature, significantly depending on the impurity content in the copper alloy. Generalizing graphical dependencies, it should be assumed that the rational phosphorus content in the alloy is in the range of 40-120 ppm. In this case, the thermal conductivity of the alloy will be in the range of 370-400 W/(m·K), the solidification temperature will be 410-440 °C, and the recrystallization start temperature will be 370-400 °C. Moreover, such a phosphorus content interval is technologically feasible to maintain during billet casting. It is also shown that normalization annealing after cold deformation in the temperature range of 320-350 °C is capable of increasing the thermal conductivity of the alloy by 1-2 %. As a result of the conducted research, optimal limits of phosphorus content in fire-refined copper were established, ensuring the level of its physico-mechanical properties not lower than the indicators characteristic of alloys obtained from cathode copper. However, besides phosphorus, other alloy impurities, the content of which differs from the values characteristic of alloys obtained from cathode copper, may affect the properties of the material made from refined copper. Therefore, further research will focus on studying their complex impact on the physico-mechanical properties of refined alloys.

Study on the effect of the application of metallic alloys on continuous casting machine segment drive roller surface

Study on the effect of the application of metallic alloys on continuous casting machine segment drive roller surface

Corrosivity study in Usiminas continuous casting machines segments

Corrosivity study in Usiminas continuous casting machines segments

Modelling smart machining process towards intelligent manufacturing - a case study

According to the concept of Industry 4.0 (even Industry 5.0) managers strive to improve production by applying information technologies and next integrating them into operational technologies, that’s enabled to transform the traditional into Intelligent Manufacturing (IM). Introduction of these changes is particularly important to improve the machining process, which is complex and dynamic. In this article the smart machining process is modelled and demonstrated for a real-world case, namely manufacturing of the die casting mould in order to increase life of the die casting mould. Therefore, firstly, the data was acquired based on the applied within a company information system and additionally on the IoT sensors from the diecasting machines, the moulds themselves and the process parameters which are used during the manufacturing process of the diecasting parts from such mould. Next, a model for predicting the life of the die-casting mould using regression analysis, based on acquired data was applied. The results of mould design and mould manufacturing process are ultimately visible on the die casting machines. Such gathered data is used to model the prediction of the possibilities for increasing life of the die casting was elaborated.

Determination of mechanical performance of boric acid filled polypropylene based polymer composites

Polypropylene (PP) polymer, which is one of the indispensable materials of our daily life and stands out with its lightness, low cost and chemical resistance properties in the industry, was used. In industrial applications where the properties of polymers without additives are not sufficient, composite materials are produced by adding some additives to the polymer. In this experimental study, the mechanical properties of composites produced by adding boric acid (BA) to PP polymer at 5 wt.% (PP/5BA), 10 wt.% (PP/10BA) and 15 wt.% (PP/15BA) ratios were investigated. the effect of both BA filler and optimum BA filler ratio on mechanical properties were investigated. In the production of PP/BA composites, granules were first produced in an industrial twin screw extruder. Then, PP/BA composite tensile and impact test specimens were moulded on a conventional injection moulding machine. As a result, it was observed that the tensile modulus, tensile and yield strength of the composite materials decreased with increasing boric acid filler content in PP polymer. Depending on the boric acid filler content, the tensile strength decreased by an average of 18.3% and the breaking strength decreased by 14.8%. The lowest tensile modulus was obtained with a value of 2713 MPa at 10wt.% boric acid filler addition. The impact strength increased slightly at 5 wt.% boric acid filler addition and decreased at 10wt.% and 15wt.% boric acid filler addition.

Mechanical and thermal properties of a newly developed sepiolite filler-filled rPET/PA11 thermoplastic nanocomposites

The study examined the impact of sepiolite filler-filled nanocomposites in a novel recycled polyethylene terephthalate (rPET)/polyamide (PA11)/joncryl® blend. Sepiolite filler significantly improved the mechanical and thermal properties of nanocomposites. A twin-screw extruder and injection moulding machines were employed to manufacture five different formulations of nanocomposites. The tensile strength (37.6 MPa) and Young's modulus (944.25 MPa) of the blend NCS-0 improved with the addition of 2 phr of sepiolite. The tensile strength and Young's modulus of nanocomposites (NCS-2) were recorded at 41.3 MPa and 974.25 MPa, respectively. The lowest sepiolite filler content (2 phr) had the maximum tensile strength among all other ratios. The flexural strength of NCS-2 was recorded at 47.3 MPa. The tensile and flexural modulus of nanocomposites were significantly enhanced by incorporating 2 phr of sepiolite. The impact strength of NCS-2 (252.98 MPa) was much higher than NCS-8. The addition of sepiolite filler increased the glass transition temperature (Tg) by 38 %. The onset of decomposition temperature (Tonset) of the blend (NCS-0) improved by 20–22° Celsius (oC). Overall, nanocomposites with 2 phr sepiolite demonstrated the ultimate mechanical and thermal properties. These results explored new ways of using rPET/PA11 compatibilized blend in the automotive industry.

Analysis of the Machine-Specific Behavior of Injection Molding Machines.

The performance of an injection molding machine (IMM) influences the process and the quality of the parts manufactured. Despite increasing data collection capabilities, their machine-specific behavior has not been extensively studied. To close corresponding research gaps, the machine-specific behavior of two hydraulic IMMs of different sizes and one electric IMM were compared with each other as part of the investigations. Both the start-up behavior from the cold state and the behavior of the machine at different operating points were considered. To complement this, the influence of various material properties on the machine-specific behavior was investigated by processing an unreinforced and glass-fiber-reinforced polyamide. The results obtained provide crucial insights into machine-specific behavior, which may, for instance, account for disparities between computer fluid dynamic (CFD) simulations and experimental results. Furthermore, it is expected that the description of the machine-specific behavior can contribute to transfer knowledge when applying transfer learning algorithms. Looking ahead to future research, it is advised to create what is referred to as a "machine fingerprint", and this proposal is accompanied by some preliminary recommendations for its development.

Expanding the technological capabilities of the twin roll casting machine.

urrently, one of the most promising areas of metallurgy development is the creation of foundry and rolling complexes based on twin roll casting machines. Their application makes it possible to organize the economical production of high-quality strips of stainless and alloy steels for critical purposes. Despite the existing experience in the creation and development of such equipment in Russia, domestic developments are still inferior to the foreign level. Thus, there is an urgent need to continue work on this topic and to create domestic industrial equipment, taking into account the latest technical solutions. At the same time, the technological capabilities of twin-roll casting machines both here and abroad are not fully used. The specialists of JSC AHK VNIIMETMASH have developed a number of the latest versions of the twin-roller casting machine with advanced technological capabilities. Due to the dosed supply of various reagents into the gap between the casting rolls-crystallizers it is possible to produce steel strips with improved properties, as well as porous aluminium strips, and also composite strips for critical applications. The article discusses the design and technological features of the proposed options for two-roller casting machines.

DESAIN KONSEP PURWARUPA MESIN INJECTION MOLDING TIPE VERTIKAL UNTUK DAUR ULANG LIMBAH PLASTIK SKALA RUMAH TANGGA

Plastic waste is the main cause of environmental pollution. It is necessary to research the design of the Injection Molding machine to process plastic waste. This study describes the design concept of a vertical type Injection Molding machine prototype by considering the factors to be utilized by small-scale plastic recycling businesses. The design stage starts from the identification of component requirements to the design of 3D drawings. The results of this study obtained a prototype design of a Vertical Injection Molding Machine. The embodiment of the design is not only determined directly by the design team and the manufacturing team, but is obtained from customer requests described in the technical specifications. At the concept design stage, there are 5 sub-functions and each function has 3 to 4 options. From the combination of these sub-functions and options, 3 assembly sketches were obtained so that 3 alternative design concepts were obtained. From the results of the concept assessment, design concept C was chosen from several alternative concepts.

A model of automated mold flux feeding into the crystallizer of a continuous casting machine

A model of automated mold flux feeding into the crystallizer of a continuous casting machine

Hexagonal Boron Nitride Nanoplatelets Filled Polyphenylene Sulphide Nanocomposites: Influence on Thermal and Dielectric Properties

The Hexagonal Boron Nitride (hBN) nanoplatelets are synthesized using a wet chemical method. X-Ray Diffraction (XRD) shows the hBN nanoplatelets exfoliates along the (002) plane. Transmission Electron Microscope (TEM) observation shows the exfoliated hBN nanoplatelets. The hBN nanoplatelets and polyphenylene suulfiude (PPS) physical mixture are solvent processed using ethyl alcohol. It involves two step processing with the first step of ultrasonic treatment of hBN nanoplatelet in ethyl alcohol followed by mixing it with PPS powder and further sonication. This mixed powder of PPS and hBN nanoplatelets are hot pressed using a compression moulding machine. With more addition of hBN nanoplatelets in PPS matrix shows the enhancement in dielectric constant. In addition, the dispersion of hBN nanoplatelets in the PPS matrix increases the crystallinity and thermal stability.

Paletli Kara Platformları için Sıvama Yöntemi ile Üretilen Alüminyum Portör Tekerlerinin Dayanımı Üzerine bir Çalışma

Conventional road wheels made by steel material for defense vehicles are generally easy and cheap in production, but it brings extra, undesirable weight to the platforms. It is found that the use of aluminum for road wheels provides weight gain on tracked land platforms. Generally, common manufacturing techniques for road wheels are casting and forging. Since load spectrum that each tracked vehicle road wheel experiences is considerably high and dynamic, casting may not be a good solution for manufacturing due to lower load absorbing capability of casting products. On the other hand, forging might be a suitable method for dynamically loaded road wheels but, it is also expensive as well due to mold and final machining cost. In this study, aluminum alloy material (2014-T6) produced by flow forming method as an alternative to steel is subjected to numerical and experimental stress and fatigue analysis for being used in road wheels of heavy tracked defense platforms. Flow forming method was utilized for effective, cheap and lighter production. Therefore, main focus was put to see the effect of flow forming method on fatigue behavior of aluminum made road wheels. It was concluded that flow forming production method of aluminum road wheel would be suitable method to provide required low cycle fatigue life with advantageous of cheapness and lightness.

Traceability System of Sand Core in Casting Production with a Digital-Twin Core Rack

In recent development of casting traceability, it has been noticed that many casting manufacturing processes that involve the use of sand cores often lack proper traceability back to the cores used in their production and the supporting production information. Most marking symbols applied to sand cores using existing marking methods not only exhibit unstable code readability but also pose critical risks to the surface quality of sand cores. In response, we developed and tested a digital-twin core rack aimed at transferring digital codes to sand cores without contact with their surfaces. By utilizing infrared sensors for real-time object detection, the core rack can transfer digital identical codes from the core-making machine to the core rack, and subsequently to the casting machine. This digital code encompasses all relevant process data of a sand core, from core making to de-coring. Moreover, the various sensors embedded in the core rack were designed to monitor air humidity, temperature, and vibration events during the transport and storage of the cores. These parameters are especially critical for maintaining the quality of inorganic sand cores. The study demonstrates the successful application of each component within this conceptual framework. Looking ahead, it is imperative to update the hardware of this concept to ensure its adaptation to the demanding conditions of an industrial environment.

Contacting of inserts with the integrated metal/plastic injection moulding

AbstractThe integrated metal/plastic injection moulding enables the production of plastics components with integrated conductor tracks and contacted inserts using an injection moulding machine. For this purpose, first a plastics carrier, which contains a groove for the later conductor track, is injection moulded and following electrical inserts are placed along the groove. The conductor track is then die‐casted from metallic solder. By using thermally conductive plastics, heat generated along the conductive paths and at the electrical inserts can be dissipated. A mechanical, electrical and optical characterisation of the material composite consisting of plastics carrier, metallic conductor track and electrical insert is carried out. In addition, process and material parameters that have an influence on the contacting of electrical inserts in connection with thermally conductive plastics in the integrated metal/plastic injection moulding are analysed. The results show that through the use of thermally conductive plastics, significant advantages in terms of heat dissipation and contact quality between the insert and the conductor track can be achieved.

Design of Horizontal Shell Core Casting Machine for Small and Medium Enterprise in the Automotive Sector

The manufacturing industry plays an important role in a country's economy because it can produce high-value products and has the opportunity to create jobs for local communities. In this study, the authors designed a horizontal shell core casting machine for small and medium enterprises in the automotive sector with a productivity of 60 seconds per cycle of products is designed based on requirements needed. This shell core casting machine is a device to produce shell core molds used to manufacture automotive components and parts. The design of this device was focused on engineering design in the form of 2-dimensional drawings and computer aided design models in 3-dimensional form. This study was done in collaboration with a local machinery manufacturer in Karawang district in Indonesia. It is expected from these designs will become a reference to manufacture shell core casting machines to support national industrialization impacted on improving the local community's economy.

Correlation of mechanical and optical properties of polypropylene plastic waste for application in composite panels

Sustainable plastic waste management systems are needed to reduce environmental pollution impacts as they are non-biodegradable and emit greenhouse gases when burned. This study investigates the feasibility of using recycled polypropylene (PP) from commonly used plastics to process composite panels. The samples were obtained from household plastics with a Resin Identification Code (RIC) of 5. In addition, other common polymer samples were obtained from plastic coffee cups (W) and red basin tubs (R) and moulded using an injection moulding machine. The mechanical strengths of the resultant composites were plotted and compared with the theoretical value of the pure polymer. The ultimate tensile strength of the white cups and the red basin tubs was found to be 36 MPa and 14.55 MPa, while their yield points were 14.45 MPa and 4.55 MPa, respectively. Infrared spectra of the absorption of the samples were obtained using Fourier transform infrared (FTIR) spectroscopy. The band gaps were analysed from Tauc’s plot and were found to be of white cups and the red bath tubs at 3.392 eV and 3.646 eV, respectively. These properties were found to be suitable for recycled plastics to be applied to process value-added panels with no significant adverse influence on material properties.

Rapid tooling of composite aluminium filled epoxy mould for injection moulding of polypropylene parts with small protruded features

Abstract Rapid tooling evolved from rapid prototyping is a novel method for developing prototype tooling rapidly using various additive manufacturing techniques. Traditional injection moulding is unsuitable for low-volume production because of the high initial cost. This study is focused on a rapid tooling approach for producing an injection mould insert for the low-volume production of plastic components. A plastic injection mould insert is designed, developed using composite aluminium filled epoxy with minute protruded features and tested on a vertical injection moulding machine as a rapid tool for low-volume production of plastic components. The composite aluminium filled epoxy (CAFE) mould insert is prepared using a wax master from silicon rubber mould prepared using a stereolithography master. Experiments are performed to determine the optimum mixing ratio of epoxy: aluminium powder for making the composite aluminium filled epoxy injection mould. The mould insert prepared was tested for the injection of polypropylene components on a vertical injection moulding machine and analyzed for dimensional accuracy. The analysis of dimensional accuracy and viability of minute features on the injected parts shows promising results for up to 30 injected parts. The injection of parts after 30 pieces resulted in increasing mould erosion and pitting, causing mould damage at the 36th injection shot. The experimental finding supports the feasibility of using the composite aluminium filled epoxy injection mould for low-volume production of the parts; however, the surface finish is inferior. The life of the mould is expected to give better results with a higher surface finish. It is also exposed that using mould release agents improves the life of the composite aluminium-filled epoxy injection mould.

Analysis of The Causes of Failure to Blow 600 ml Bottles on Blow Molding Machine with The Fishbone Diagram

Analysis of The Causes of Failure to Blow 600 ml Bottles on Blow Molding Machine with The Fishbone Diagram