Equipment of foundry shops

Ministry of Education and Science of the Republic of Kazakhstan

Karaganda State Technical University

 

 

 

Confirmed by

Chairman of  Academic Council,

rector, RK NAS academician

Gazaliyev A.M.

_______________________

_________ ____, 20___.

 

 

 

 

 

Syllabus

 

 

Course EDFS 3310 «Equipment of foundry shops»

Module PED 29 « Production equipment and designing»

Major  5В070900 – «Metallurgy»

 

        Mechanical Engineering Institute

Department of Metallurgy, Materials Science and Nanotechnology

 

2012

 

Preface

 

Syllabus is worked out by cand.of sc., associate professor Kipnis L.S., senior tutor Medvedeva I.E., senior tutor Malashkevishut E.I.

 

 

 

Discussed at the meeting of the department «Metallurgy, Materials Science and Nanotechnology»

Minutes № _______ of ______________ «____» 20___

Head of department ________________    ___________«____» 20___

(signature)

 

 

 

Approved by the  Educational Consil of  Institute of Mechanical Engineering

Minutes №  _______ of ______________ «____» 20___

 

Chairman  ________________        ____________ «____» 20___

(signature)

 

 

 

 

Tutor’s personal data and contact information

 Kipnis Lev Semenovich сand.of  Sc., associate professor of «Metallurgy, Materials Science and Nanotechnologies» department, Medvedeva Irina Evgenevna senior tutor of «Metallurgy, Materials Science and Nanotechnologies» department, Malashkevishute Elena Izoasovna senior tutor of «Metallurgy, Materials Science and Nanotechnologies» department.

 

 

«Metallurgy, Materials Science and Nanotechnology » chair is in  main building of KSTU (56, Mira blvd.), room 313, contact phone 56-59-35 add. 1024.

 

Course labour intensity

 

Term	Number of credits / ЕCTS	Type of classes					number of AL	Total number of hours	Forms of Control
		Number of contact hours			number of OH	Total hours
		lectures	Practical classes	Laboratory classes
7	3	30	15	–	45	135	45	135	Examination,  Course work

 

Course description

Course «Equipment and design of foundry shops » is high school a cycle of profile courses. Purpose of studying of  given course is to acquaint students with a technique of designing of casting shops and factories, modern design solutions in  field of foundary and main routes of development of designing.

 

 

Course purpose

Purpose of studying of  given course is to acquaint students with a technique of designing of casting shops and factories, modern design solutions in  field of foundary and main routes of development of designing.

 

Course objectives

As a result of studying of this course:

student knows:

– following: to give to  future specialists of knowledge of modern norms, algorithms and  basic trends of development of designing of casting shops of  factories. As a result of studying of  given course students should:

– to know design philosophies of departments and foundary factories.

nobility modern rules and norms of designing of casting shops and ir branches,  typical equipment and space-planning solutions for departments of different type.

–         to be able to carry out design calculations, to choose production engineering and  equipment, to make grading of casting shops, branches, sections, auxiliary services.

–         to get practical skills in  analysis of an equipment lay-out and  manufacture organisation under drawings or in acting departments, in performance of design drawings of casting shops and sections.

 

Prerequisites

Studying of this course requires assimilation of the following courses (with the indication of sections subjects)):

 

 

Post requisites

The knowledge received at studying of course « Equipment and design of foundry shops », is used at development of following courses:

1. Exhaust work

 

Thematic plan of course

 

 

List of practical (seminar) classes

1. Studying of technical datas and features of an arrangement of a standard equipment

2. Methods of calculation of  production program of department

3. Calculation of  program and sampling of composition of  process equipment of industrial branches

4. A technique of working out of lay-out of an arrangement of  process equipment,  analysis of typical solutions

5. Studying of methods of registration of  design documentation,  sped up computer designing

 

Thematic plan of office hours

 

OH theme	Objectives	Form classes	Contents of classes	Recommended literature
1	2	3	4	5
1.Designing organisation	Deepening of knowledge on  given me	Analysis of references	Norms of technological designing	[1, 2, 4]
2.Calculations of programs and designing of branches of department	Deepening of knowledge on  given me	Problem solving	Programs of branches of a casting shop, calculation of  charge of materials	[2, 4, 6, 8]
3.Designing of auxiliary branches and services	Deepening of knowledge on  given me	Problem solving	Sampling and calculation of number of units of equipment	[1, 2, 13]
4.Calculations of programs and designing of departments of special ways of casting	Deepening of knowledge on  given me	Problem solving	Designs of departments centrifugal, кокильного, etc. ways of casting	[3, 10, 11, 12]
5.Calculations to designs of redesign and modernisation of departments	Deepening of knowledge on  given me	Problem solving	Designs of redesign and modernisation of departments	[2, 5, 7, 9, 11, 12]

 

 

Subjects of control tasks for AL

1.  Individual task under  equipment layout analysis

2.  Individual task on equipment selection

 

 

 

 

 

Criteria of students’ knowledge assessment

The examination mark is determined by course as the sum of the maximum indexes of progress on midterm controls (to 60%) and to final attestation (examination) (to 40%) and makes value to 100% according to the table.

 

Grade «A» (excellent) is put in the case if student during a term showed perfect knowledge of all program questions of course, and also of mes of independent work, regularly handed over midterm tasks, showed independence in studying of theoretical and applied questions according to the main program of studied course, and also on extra program questions.

Grade «A-» (excellent) stipulates perfect knowledge of basic laws and processes, concepts, ability to generalization of theoretical questions of course, regular handing of midterm tasks of classroom and independent work.

Grade  “B+” (good) is put in the case if student showed good and excellent knowledge of course questions, regularly handed over term tasks generally on “excellent” and some on “good”.

Grade “B” (good) is put in the case if student showed good knowledge of the questions opening the main maintenance of a concrete me of course, and also me of independent work, regularly handed over term tasks on “good” and “excellent”.

Grade “B-” (good) is put to a student in the case if he well is guided in theoretical and applied questions of course both on classroom, and on AL mes, but irregularly handed over midterm tasks and had cases of a repeating an examination of term tasks on course.

Grade “C+” (satisfactory) is put to a student in the case he owns questions of conceptual character by all types of room classes and AL, can open the maintenance of separate modules of course, hands over on “good” and “satisfactory” term tasks.

Grade “C” (satisfactory) is put to a student in the case he owns questions of conceptual character by all types of room classes and AL, can open the maintenance of separate modules of course, hands over on “satisfactory” term tasks.

Grade “C-” (satisfactory) is put to a student in the case student during a term regularly handed over term tasks, but concerning room classes and AL owns only the general concepts and can explain only separate regularities and their understanding within a concrete me.

Grade “D+” (satisfactory) is put to a student in the case he irregularly handed over term tasks concerning room classes and AL owns only the general concepts and can explain only separate regularities and their understanding within a concrete me.

Grade “D-” (satisfactory) is put to a student in the case he irregularly handed over term tasks, concerning room classes and AL, owns the minimum volume of knowledge, and also allowed admissions of classes.

Grade “F” (unsatisfactorily) is put when student practically doesn’t own the minimum theoretical and practical material of room classes and AL on course, irregularly visits classes and doesn’t hand over in time term tasks.

Midterm control is carried out on the 7, 14 weeks of study and it develops        proceeding from the following types of control:

 

 

Policy and procedures

At the studying course ” Equipment and design of foundry shops ” I ask to observe the following rules:

1. Not to be late for classes.

2. Not to skip classes without a good reason, in case of an illness I ask to provide the reference, in other cases – an explanatory note.

3. Duties of the student include visit of all types of occupations.

4. According to the schedule diagram of educational process to hand over all types of control.

5. To fulfill the passed practical and laboratory researches in time specified by the teacher.

6. To fulfill the passed lecture classes (irrespective of the reason) in the form of the paper on the passed me.

7. Actively to participate in educational process.

8. To be tolerant, open, frank and benevolent to fellow students and teachers.

 

 

 

Educational and methodical provision of course

 

Author	Literature	Publishing house, year of the issue	Number of copies
			at library	at department
Main literature
Фанталов Л.И., Кнорре Б.В. и др. –	Основы проектирования литейных цехов.	М.: Машиностроение, 2009.	15	–
Е.С. Ямпольский	Проектирование машиностроительных заводов и цехов. Справочник. Т.1, 2, 6.	М.: Машиностроение, 2004	25	–
Сафронов В.Я.	Справочник по литейному оборудованию	М.: Машиностроение, 2006	2	–
Л.С.Кипнис, А.З.Исагулов, Д.К.Исин	Проектирование литейных цехов: Учебное пособие.	Караганда: КарГТУ, 2003. 83 с.	2	–
	Оборудование  для литейного  и сварочного производств:  Номенклатурный  каталог.	М.: Информационная фирма «Каталог».  2000.	25	2
Лузгин И.П.	Индукционные печи  средней частоты нового поколения	Металлургия машиностроения. 2002. №1	25	2
	Магнитодинамические установки для плавки и обработки металла	Металлургия машиностроения. 2002. №4.	2	–
	Цветное литье: Справочник	М., Машиностроение, 2001
Additional literature
	Специальные способы литья: Справочник	М.: Машиностроение, 1991.	10	–
	Типаж технологического оборудования для литейного производства на 1995г.	М.:  Изд. НИИМАШ, 2000.	10	2
Сокол И.Б.,	Роботизированный комплекс изготовления форм для ЛВМ	Литейное производство, 1997.  № 10	1	1
	Робототехнические комплексы в машиностроении	2002	35	–

 

 

 

 

 

Schedule of performing and handing in assignments on course

Type of control	Purpose and content of assignment	Recommended literature	Duration	Form of control	Handing term
1	2	3	4	5	6
Avenue. №1	Studying of technical datas and features of an arrangement of a standard equipment	[1] p. 64 136, [3] p. 38 98	2 weeks	current	2nd week
Report on OH	Modern  smelting and forming  equipment	[1] p. 63-138, [2] p. 110-153, [5] p. 22-59	2 weeks	current	2nd week
Avenue №2	Methods of calculation of  production program of department	[4] p. 28 46	4 weeks	current	4th week
Test interrogation	Attaching of oretical knowledge and practical skills	Abstract of lectures	1 contact Hour	baudray	7 thweek
Report on OH	Programs of departments mass and a batch production	[1] p. 30-206, [4] p. 25-53	2 weeks	current	3rd week
Avenue № 3	Calculation of  program and sampling of composition of  process equipment of industrial branches	[4], p. 25-92	4 weeks	current	7th week
Test interrogation	Attaching of oretical knowledge and practical skills	abstract of lectures	1 contact Hour	baundry	14th week
Report on OH	Programs and  process equipment of branches of fusion, формовки, casting clearings	[1] p. 210-256, [2] p. 45-63, [5] p. 35-72, [11] p. 32-59	2 weeks	current	4th week
Avenue № 4	Technique of working out of lay-out of an arrangement of  process equipment,  analysis of typical solutions	[1] p. 232-259, [4] p. 96-106	3 weeks	current	9th week
Report on OH	plot of an arrangement of  process equipment of department	[1] p. 232-280		current	5th week
Avenue № 5	Studying of methods of registration of  design documentation,  sped up computer designing	[4] p. 98-102	2 weeks	current	11th week
Report on OH	Modern production engineering of  sped up computer designing	Periodicals	1 week	current	13th week
Protection  course slave.			2-13 week	total	14 week
Examination	Check of assimilation of a course material	All list of the main and additional literature	2 contact hours	Final	During examination period

    

Questions for self-checking

1.  Maintenance of  detailed design of a casting shop.
2. Composition of  detail design of a casting shop.
3. Classification of casting shops.
4. Appointment and  maintenance of norms of technological designing.
5. Operating mode of casting shops. Sampling of an operating mode of department.
6. Operating time funds, ir maintenance and calculation.
7. Types  Maintenance of  detailed design of engineering works.
8. Specialisations of casting shops. Value of specialisation.
9. Composition of  production program of a casting shop.  program analysis.
10. Ways of calculation of capacities of a casting shop ( exact, resulted and conditional production programs).
11. Calculation of capacities of  smelting branches.
12. Calculation of capacities of forming branches ( exact and resulted program).
13. Calculation of capacities of forming and rod branches ( conditional program).
14. Calculation of capacities of rod branches.
15. Calculation of annual requirement in forming and a core sand.
16. Definition of annual requirement for moulding materials.
17. Calculation of powers branches.
18. Calculation of capacities and  squares of shop warehouses.
19.  basic process equipment of forming branches of departments of mass production
20. Basic elements of  automated lines, ir lay-out.
21. Typical lay-out of foundry conveyors for manufacture of small and average handsheets.
22. Typical lay-out of foundry conveyors for manufacture of large handsheets.
23. Definition of key parametres of foundry conveyor lines and  squares occupied with m.
24. Typical lay-out and  equipment of branches large and heavy casting.
25. Scope and essence of a principle of “floating equipment» at manufacturing of forms and rods.
26.  Basic process equipment of rod branches of departments of mass production; sampling and an arrangement.
27.  Basic process equipment of  smelting branches iron both steel departments; sampling and an arrangement.
28. Design procedure of quantity of  process equipment of casting shops.
29. Calculation of annual requirement of a casting shop in shiht materials.
30.  Organisation of furnish,  complete equipment and warehousing of rods.
31. Ways of transportation and delivery of rods to setting points in forms.
32. Constructive elements of buildings of departments, ir basic sizes.
33. Sampling of a mutual bracing of branches in a department building.
34.  Process equipment branches and  circuit design of its arrangement.
35.  Equipment and lay-out terms branches of small casting.
36.  Equipment and lay-out terms branches of large casting.
37. Demands to configuration of casting shops. Alternatives of  form of buildings of departments, ir analysis.
38.  Organisation of design works. Design stages of casting shops.
39. Block and central circuit designs of systems.
40.  Systems of regeneration of sand in departments mass and a batch production.
41.  Calculation of annual requirement for lining materials.
42.  Definition of quantity of workers for designed department.