1.
P. Larsen, K. Paw Madsen, J. Trojan
DISA Industries A/S, Taastrup, Denmark
THE DIGITAL FOUNDRY OF TOMORROW
2.
G. Hajas
Alu-Onto, Ltd., Hungary
MOULD FILLING AND MECHANICAL PROPERTIES OF GRAVITY SAND CASTINGS HAVING LARGE GEOMETRY AND THIN WALL /1-3MM/- BY A NEW CASTING PROCESS
3.
U. Klančnik, A. Stergar, J. Bojanovič, M.Drobne
Valji, d.o.o. Slovenia
IMPACT OF MOLD ROTATION VELOCITY ON DISTRIBUTION OF MICROSTRUCTURAL CONSTITUENTS IN CAST IRON
1.
P. Larsen, K. Paw Madsen, J. Trojan
DISA Industries A/S, Taastrup, Denmark
THE DIGITAL FOUNDRY OF TOMORROW
Abstract
The constant pursuit of new ways to boost efficiency, enhance productivity, improve casting quality and unlock savings – preferably all at the same time – is ubiquitous and universal in the foundry industry. Irrespective of foundry size and type, location and customer market, they remain factors that all foundries can relate to and try to optimize – every day, bit by bit.
Industry 4.0 is a recurring theme in conversations around the foundry of tomorrow and the concept plays an important role in the evolution towards future foundry models. A lively exchange is taking place between software developers and leading engineers in foundries, to take the advantages of IoT (Internet of Things) technologies into day-to-day foundry operations. But what are these opportunities?
Today, process data from individual machines is still typically stored across multiple, separate systems, hampering the transparency and accessibility needed for real-time data analysis and direct intervention. Achieving the latter under these circumstances is not impossible, but usually very inefficient and difficult. Pulling in valuable historical data is also cumbersome.
The challenge is to ensure easy access to all data across a production system, to efficiently monitor and control processes in real time. Collecting data streams from the whole casting process (i.e. sand, moulding and metal data) in a single system opens up many new opportunities. Fundamentally, improved access to data makes analysis and monitoring much easier, which in turn speeds up troubleshooting.
The presentation will cover several new possibilities around data collection and analysis, including sustainable profitability, process data and monitoring.
Keywords: Green sand moulding, DISAMATIC, Process data, Production digitalizing, Industry 4.0, Internet of things
2.
G. Hajas
Alu-Onto, Ltd., Hungary
MOULD FILLING AND MECHANICAL PROPERTIES OF GRAVITY SAND CASTINGS HAVING LARGE GEOMETRY AND THIN WALL /1-3MM/- BY A NEW CASTING PROCESS
Abstract
Alu-Onto Ltd. has patented a sandcasting process with which a thin wall (1 – 3 mm) casting design can be turned into a real-life workpiece within weeks. These castings are perfect functional prototypes of high-pressure die casting (HPDC) parts. Prototype castings can be heat treated to fulfill different mechanical property requirements. Applications include castings for prototype vehicles build for crash tests, special vehicle conversions, vehicles produced in small numbers, but also LED streetlight prototypes have been made using this technology.
Keywords: aluminium sand casting process, prototypes of HPDC parts,
3.
U. Klančnik, A. Stergar, J. Bojanovič, M.Drobne
Valji, d.o.o. Slovenia
IMPACT OF MOLD ROTATION VELOCITY ON DISTRIBUTION OF MICROSTRUCTURAL CONSTITUENTS IN CAST IRON
Abstract
Cast rolls for hot rolling are two layered cast ingots composed of a harder, more resistant outer layer made of alloyed cast iron and a tough core made of nodular cast iron. The outer layer is nowadays most often centrifugally cast, while the core is cast statically. A lot of research has been done on the physics of centrifugal casting with emphasis on aluminum alloys reinforced with SiC. Previous research shows a correlation between the mould rotation speed and the occurrence of hot tearing, raining, carbide segregation, lamination and its impact on the rate of solidification. The goal of the present study was to establish a possible correlation between mould rotation speed and the distribution of microstructural constituents, such as eutectic carbides and graphite, in a highly alloyed cast iron for work layers in rolls. Results confirm a difference in as-cast microstructure between three different rotating speeds especially in precipitation of graphite, the form of eutectic carbides and bulk hardness. Understanding the implications of rotating speed influence on as-cast microstructure can help improve the quality of the finished product and to avoid serious casting failures.
Keywords: centrifugal casting, rotating speed, alloyed cast iron, microstructure