Optimization of the Production Process of Vibrocasted Refractory Products

Abstract

This paper deals with the optimization of the production process of vibrocasted refractory products. The main goal is to make efficient and automate the production of moulds for refractory blocks. A theoretical research was followed by an expert analysis of the current state of the manufacturing process at an industrial partner. The next step was to analyze complete portfolio of refractory vibrocasted products, which results in choosing a representative sample whose dimensions most correspond to majority of the moulds produced. Subsequently, a design was done, to make the production process more effective with respect to time, technology and construction aspects, focusing on increasing productivity, reducing human labour and increasing production modernization. In the end, the design options were evaluated in terms of time and cost, and the ideal process of the manufacturing production was recommended with respect to the latest technology. It includes a solution for material composition and optimized design of moulds for vibrocasted refractory materials to increase production efficiency moulds and cost reduction while maintaining mould accuracy and quality. These products are subject to high demands in terms of material quality and precision, and at the same time costly to produce due to manual manufacturing.

Analysis and Quality Assessment of Refractories Formed under Reduced Pressure

“…Therefore, it is preferable to have a large number of small pores in the product, compared to the same volume of large pores [4,11,12]. b) the mechanical properties of the analysed materials determine the resistance of the finished products to external and internal stresses [3]. one such property is the compressive strength -ccs (from cold crushing strength).…”

“…refractory materials are widely used in the foundry industry [3,4,7,17]. They are used both in the metal melting subsystem (as lining of furnaces, drain gutters, etc.)…”

“…There are several methods of ensuring a sufficiently low level of porosity. The most common their parameter is the frequency of vibratory compaction and the duration of this process [3]. in this paper, the authors have proposed the use of reduced pressure moulding as a method to assist in obtaining a higher apparent density of the final product.…”

The Effect of Vacuum Forming on the Quality of Refractory Materials

“…The mechanical properties of refractory materials determine the strength of the finished products toward external and internal stresses [11]. The parameter studied is the compressive strength, i.e., CCS (Cold Crushing Strength).…”

“…The parameter studied is the compressive strength, i.e., CCS (Cold Crushing Strength). Refractory materials used, for example, in the lining of blast furnaces are mainly subjected to compressive stresses [11]. The lower the compressive strength, the greater the chance that the furnace lining will crack in the event of a misfiring [12].…”