Operation optimization of holding furnaces in special casting shops

Dotsenko, Yuri; Доценко, Наталія Андріївна; Tkachyna, Yevhenii; Fedorenko, Vadym; Tsybulskyi, Yevhenii

doi:10.15587/2312-8372.2018.150585

Cited by 6 publications

(4 citation statements)

References 6 publications

(3 reference statements)

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“…In this case, the control task is expanded to the level of control of the duplex smelting process [23], which requires considering the control object as a combined electrotechnological complex [26,27] integrated with the cupola complex and other equipment of the foundry. In this case, integration into a common technological flow allows to represent the cupola process as part of the general technological process for manufacturing castings, considered from the standpoint of an organizational and technical queuing system [28]. It is natural to assume that with such an approach, all temporary operations of the processes must be coordinated.…”

Section: Engineeringmentioning

confidence: 99%

Experimental and industrial method of synthesis of optimal control of the temperature region of cupola melting

Demin¹

2023

Eureka: PE

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The object of research is the temperature regime of melting in a cupola. The synthesis of optimal control of such an object is associated with the presence of a problem consisting in the complexity of its mathematical description and the absence of procedures that allow one to obtain optimal control laws. These problems are due to the presence of links with a pure delay, non-additive random drift, and difficulties in controlling the process parameters, in particular, accurately determining the temperature profile along the horizons and the periphery of the working space of the cupola. The proposed conceptual solution for the synthesis of optimal temperature control allows the use of two levels of control: the level controller solves the problem of maintaining the constant height of the idle charge, and the problem of increasing the temperature of cast iron is solved by controlling the air supply to the tuyere box. It is shown that the problem of regulating the upper level of an idle charge can be solved by reducing the model of the regulation process to a typical form, followed by the use of the Pontryagin maximum principle. A procedure for the synthesis of optimal air flow control is proposed, which makes it possible to obtain the temperature regime control law on the basis of experimental industrial studies preceding the synthesis process. This takes into account the time delay between the impact on the object and its reaction, which makes it possible to predict the temperature value one step acharge, equal to the time interval during which the lower surface of the fuel charge reaches the upper surface of the level of the idle charge. A procedure for temperature profile control based on the use of D-optimal plans for selecting sensor installation points is proposed. Due to this, it becomes possible to determine the temperature profile of the cupola according to its horizons and the periphery of the working space of the cupola with maximum accuracy. The proposed synthesis method can be used in iron foundries equipped with cupolas, as it is a tool for studying a real production process, taking into account its specific conditions. This will allow developing or improving control systems for cupola melting, implementing different control modes: manual, automated or automatic

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Section: Engineeringmentioning

confidence: 99%

Experimental and industrial method of synthesis of optimal control of the temperature region of cupola melting

Demin¹

2023

Eureka: PE

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“…It should be noted that optimization of melt and mold manufacturing technology alone is not enough, given the productivity criterion, which is very important for production. Therefore, it is necessary to solve the problem of maximum consistency in the operation of the melt, mold assembly and pouring sections, which is possible by modeling this system as a queuing system, for example, as presented in [28]. In particular, it is important to coordinate the operation of holding furnaces, which can be electric mixers, acting as a secondary unit of the duplex melt process, and providing the pouring section of the casting conveyor with the required amount of alloy of a given quality in terms of chemical composition and temperature.…”

Section: Introduction the Object Of Researchmentioning

confidence: 99%

Improving technology for manufacturing casting case of truck clutch release cylinder

Demin

2023

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The object of research: Manufacturing technology of body castings for trucks using the example of a clutch release cylinder body made of gray cast iron with flake graphite EN-GJL-200. Investigated problem: Finding ways to reduce the weight and size characteristics of cast parts. The main scientific results: A mathematical model has been developed that has made it possible to determine the optimal compositions of alloying Cr/Ni – Cu/Ti complexes that ensure an increase in the grade of cast iron by increasing the tensile strength at elevated carbon contents. This makes it possible in the future to reduce the thickness of the walls of the castings, achieving a reduction in their weight and size characteristics The area of practical use of the results of the study: Automotive industry in terms of technology for manufacturing cast parts for trucks Innovative technological product: Improved technology for manufacturing the clutch release cylinder body due to optimization of melt technology and out-of-furnace processing allows for targeted selection of melt processing modes, ensuring an increase in the strength characteristics of cast iron for cast body parts, thereby moving from the EN-GJL-200 cast iron grade to the EN grade -GJL-250 and EN-GJL-300. The scope of the innovative technological product: Foundries of engineering enterprises, in particular those producing trucks, in which iron castings are produced

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“…Fierce competition in the market of metal products, in particular, products of metallurgical production and mechanical engineering, is the factor that stimulates the development of technological innovations in industrial production [1,2]. Such innovations are optimal technological solutions in terms of melting [3][4][5][6] and out-of-furnace processing of melts [7][8][9][10]. The alloys obtained in this case are used for cast machine parts, therefore, the operational reliability of the corresponding units and mechanisms directly depends on the quality of the alloy.…”

Section: Introductionmentioning

confidence: 99%

Increasing the mechanical properties of structural cast iron for machine-building parts by combined Mn – Al alloying

et al. 2022

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The object of research in this work was cast iron for machine-building parts, alloyed with Al. The possibility of improving the mechanical properties of cast iron by choosing the optimal Mn – Al combinations, depending on the carbon content in the cast iron, was determined. The study was carried out on the basis of available retrospective data of serial industrial melts by constructing the regression equation for the ultimate strength of cast iron in the three-factor space of the input variables C – Mn – Al. The optimization problem was solved by the ridge analysis method after reducing the dimension of the factor space by fixing the carbon content at three levels: C = 3 %, C = 3.3 %, and C = 3.6 %. It was found that the maximum values of the ultimate strength are achieved at the minimum level of carbon content (C = 3%) and are in the range of values close to 300 MPa. In this case, the Al content is in the range (2.4–2.6) %, and the Mn content is about 0.82 %. With an increase in the carbon content, there is a tendency to a decrease in the content of Mn and Al in the alloy, which is necessary to ensure the ultimate strength close to 300 MPa. The results of the ridge analysis of the response surface also showed that at the upper limit of the carbon content (C = 3.6%), it is not possible to reach the ultimate strength of 300 MPa in the existing range of Mn and Al variation. All solutions are verified for the following ranges of input variables C = (2.94–3.66) %, Mn = (0.5–1.1) %, Al = (1.7–2.9) %. Graphical-analytical descriptions of the optimal Mn – Al ratios are obtained, depending on the actual content of carbon in the alloy, which make it possible to purposefully select the optimal melting modes by controlling the tensile strength of the alloy

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Operation optimization of holding furnaces in special casting shops

Cited by 6 publications

References 6 publications

Experimental and industrial method of synthesis of optimal control of the temperature region of cupola melting

Experimental and industrial method of synthesis of optimal control of the temperature region of cupola melting

Improving technology for manufacturing casting case of truck clutch release cylinder

Increasing the mechanical properties of structural cast iron for machine-building parts by combined Mn – Al alloying

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