618-1415/01 – Metalcasting for Automotive Parts (SAD)

Gurantor departmentDepartment of Metallurgy and FoundryCredits8
Subject guarantordoc. Ing. Petr Lichý, Ph.D.Subject version guarantordoc. Ing. Petr Lichý, Ph.D.
Study levelundergraduate or graduate
Study languageCzech
Year of introduction2013/2014Year of cancellation
Intended for the facultiesFMTIntended for study typesBachelor
Instruction secured by
LoginNameTuitorTeacher giving lectures
KRO226 Ing. Ivana Kroupová, Ph.D.
LIC03 doc. Ing. Petr Lichý, Ph.D.
RAD913 Ing. Filip Radkovský
Extent of instruction for forms of study
Form of studyWay of compl.Extent
Full-time Credit and Examination 3+3

Subject aims expressed by acquired skills and competences

Student will be able to analyse and compare basic methods of mould- and core-making; Student will be able to describe basic processes during forming a casting from pouring it up to metal cooling; Student will be able to explain the formation of the most important casting defects; Student will be able to describe material and foundry properties of cast materials for automotive industry.

Teaching methods

Lectures
Seminars
Tutorials
Experimental work in labs
Project work

Summary

1st Overview of castings for the automotive industry. Technological flow production in the foundry. 2nd Casting the single sand molds. Moulding Materials - grog, binders. 3rd Moulding Materials I-IV. generation. Properties of molding and core mixtures, testing. 4th Technology of production of sand molds and cores. Production of precision automotive castings. Shell formation, the use of lost and odpařitelného model. 5th Metal casting molds. (Gravity, pressure, low pressure, centrifugal). 6th The flow of molten metal in the gating system, the fluidity of metal, static and the dynamic effect of the metal form. 7th Solidification and crystallization of the metal. Gases in metals and in shape. 8th Volumetric shrinkage of metal and its consequences. Heat units and their Disposal 9th Linear shrinkage in castings. The emergence of tensions in the castings. 10th Development of technological process of casting. Casting defects. 11th Materials for castings. Cast iron - structure, formation of graphite, basic metal compound. Mechanical properties of cast iron. 12th Metallurgy of cast iron - vaccination and modification 13th Automotive castings of nonferrous metals. Aluminum alloys and magnesium. 14th Metallurgy of Al and Mg.

Compulsory literature:

[1] SCHLEG, Frederick P. a Frederick H. KOHLOFF. Technology of metalcasting. Des Plaines: American Foundry Society, c2003. ISBN 0-87433-257-5.

Recommended literature:

[1] CAMPBELL, John. Castings. 2nd ed. Oxford: Elsevier Butterworth-Heinemann, 2003. ISBN 0-7506-4790-6.

Way of continuous check of knowledge in the course of semester

1 classified test report 2 classified programs 1 classified seminar paper and its defence

E-learning

http://www.fmmi.vsb.cz/cs/okruhy/studium-a-vyuka/podklady-ke-studiu

Další požadavky na studenta

There are not additional requirements on students in the field of this subject.

Prerequisities

Subject has no prerequisities.

Co-requisities

Subject has no co-requisities.

Subject syllabus:

Lectures: 1. Foundry industry in the Czech republic and in the world, statistics, possibilities and limits of casting production. Procedure of casting production from a design to the dispatch department 2. Applied processes and techniques in foundries. Production of castings using permanent metal mold and lost sand mold 3. Molding materials, sand, binders, mold and core making technologies, molding mixtures making and testing 4. Sand reclamation techniques – dry, wet, thermal reclamation 5. Melt flow in molds,castability, running system design and calculation 6. Static and dynamic action of the melted alloys on molds and cores. Gases in metals and molds 7. Castings crystallization and solidification 8. Solidification shrinkage – feeding (risers) 9. Linear contraction of the casting, hot tearing, cold cracking, residual stresses 10. Materials for casting production, cast steel 11. Cast irons - types, structures, mecanical properties 12. Cast iron – melting, secondary metallurgy, innoculation 13. Non ferrous alloys for casting - metallurgy, properties 14. Terminal consultation practices 1. Refractory materials for mold and core making, silica and non silica sands, organic and inorganic binders 2. Molding mixtures making and testing -– test report 3. Mold and core making technologies, split pattern, simple and complex mold, core making by compactin or hardening 4. Molding and pouring the own AlSi alloy casting 5. Visit of a cast iron foundry and its pattern shop 6. Casting design, axonometric drawing 7. Calculation of metalostatic pressure and buoyancy 8. Casting designing- parting line, scarfs, working allowance 9. Visit of a hight pressure die casting aluminium alloys foundry 10. Running system design and calculation (program) 11. Calculation of the riser volume ( program) 12. Cast irons, steels, standards, properties, metallografy 13. Seminary Rapid prototyping , computer simulations 14. Final seminary, credit

Conditions for subject completion

Full-time form (validity from: 2013/2014 Winter semester)
Task nameType of taskMax. number of points
(act. for subtasks)
Min. number of points
Exercises evaluation and Examination Credit and Examination 100 (100) 51
        Exercises evaluation Credit 30  15
        Examination Examination 70  21
Mandatory attendence parzicipation:

Show history

Occurrence in study plans

Academic yearProgrammeField of studySpec.FormStudy language Tut. centreYearWSType of duty
2019/2020 (B3923) Materials Engineering (3911R034) Materials and Technologies for Automobile Industry P Czech Ostrava 2 Compulsory study plan
2018/2019 (B3923) Materials Engineering (3911R034) Materials and Technologies for Automobile Industry P Czech Ostrava 2 Compulsory study plan
2017/2018 (B3923) Materials Engineering (3911R034) Materials and Technologies for Automobile Industry P Czech Ostrava 2 Compulsory study plan
2016/2017 (B3923) Materials Engineering (3911R034) Materials and Technologies for Automobile Industry P Czech Ostrava 2 Compulsory study plan
2015/2016 (B3923) Materials Engineering (3911R034) Materials and Technologies for Automobile Industry P Czech Ostrava 2 Compulsory study plan
2014/2015 (B3923) Materials Engineering (3911R034) Materials and Technologies for Automobile Industry P Czech Ostrava 2 Compulsory study plan
2013/2014 (B3923) Materials Engineering (3911R034) Materials and Technologies for Automobile Industry P Czech Ostrava 2 Compulsory study plan

Occurrence in special blocks

Block nameAcademic yearForm of studyStudy language YearWSType of blockBlock owner