632-0802/02 – Theory of Foundry Engineering Processes II. (TSP II)

Gurantor departmentDepartment of Materials and Technologies for VehiclesCredits5
Subject guarantorprof. Ing. Tomáš Elbel, CSc.Subject version guarantorprof. Ing. Tomáš Elbel, CSc.
Study levelundergraduate or graduateRequirementCompulsory
Year1Semestersummer
Study languageCzech
Year of introduction2003/2004Year of cancellation2013/2014
Intended for the facultiesFMTIntended for study typesFollow-up Master
Instruction secured by
LoginNameTuitorTeacher giving lectures
BED47 doc. Ing. Vlasta Bednářová, CSc.
ELB77 prof. Ing. Tomáš Elbel, CSc.
HAN47 Ing. Aleš Hanus, Ph.D.
KOZ36 Ing. Petr Kozelský, CSc.
Extent of instruction for forms of study
Form of studyWay of compl.Extent
Full-time Credit and Examination 3+2

Subject aims expressed by acquired skills and competences

The student will be able as follows: to know the rules for obtaining good casting with no defects; to define the basic thermal and physical quantities of heat transfer in sand and metal moulds; to apply the metal filtration aids during pouring and feeding of metal during solidification; to solve the degasification and venting of a foundry mould.

Teaching methods

Lectures
Seminars
Individual consultations
Tutorials
Experimental work in labs

Summary

Processes taking place in a solidifying and cooling-down casting - definition of the physical magnitudes and terms - characteristics of heat-flow rates in a casting - transfer of heat in a solidifying casting and in a sand mould - determination of the time intervals of solidification of castings - modelling of thermal processes at solidification and cooling-down of castings - solidification of castings in metallic moulds, origination of gap between casting and mould - shrinkage of metals and alloys - directional solidification - theoretical and experimental analysis of risering - elimination of the thermal nodal sites in castings - filtering of melt through a double-phase zone - segregation and liquation - cooling-down intervals of castings - shrinkage of castings - stress in a casting - consequences of stress in the castings.

Compulsory literature:

CAMPBELL, J.: Castings, Butterworth-Heinemann. Oxford, 2000. SCHLEGG,F.P. et al. Technology of Metalcasting , AFS Publication, 2003.

Recommended literature:

STEFANESCU,D,,M. : Science and Engineering of Casting Solidification.Cluver Academic/Plenum Publishers, New York, 2002. DANTZIG,J.A.;RAPPAZ,M. : Solidification, EPFL Oress, Boca Raton,2009

Way of continuous check of knowledge in the course of semester

One test Two scores projects

E-learning

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

Další požadavky na studenta

One test Two scores projects

Prerequisities

Subject has no prerequisities.

Co-requisities

Subject has no co-requisities.

Subject syllabus:

Lectures: 1. Mould and metal coefficients in heat transfer on the metal/mould interface. 2. Thermal expansion coefficient. 3. Fuliid pressure in metals. Gating system calculation and aids. Filtering of the metal. 4. Freezing and solidification of castings in metallic mould. Air gap formation. 5. Growth of the solid. Segragation (dendritic, gravity). Thermal gravity convection 6. Macro-modelling of solidification. Physical and numerical methods. 7. Metal reoxidation in the mould cavity. Transport of gas in metal and mould cavity. 8. The angle of inner feeding channel. Directional solidification in hot spots. 9. Infiltration (penetration) of feeding metal in dendritic skeleton. 10. Riser optimalization. Feeding aids. 11. Thermal and transformation stress. Measurement and reduction of residual stress in casting. 12. The use of acoustic emission method for the study of discontinuity defects in castings. 13. The wall movement of a mould. 14. Rules to obtain the correct and conform casting. Practice: 1st Safety Training 2nd Determination of the constant freezing (wax). 3rd Modelling of solidification thermal nodes paraffin. 4th Pouring tests on steel - chladítek influence the course of solidification 5th The temperature field of casting I 6th The temperature field of casting II. 7th Linear shrinkage - steel, aluminum alloy. 8th Linear shrinkage - iron. 9th Tensions in the casting, casting bars I. 10th Tensions in the casting, casting bars II. 11th Strength and plastic properties of steel in the solidus. 12th Acoustic emission 13th Simulation of solidification using the computer (calculating solidification basic shapes) 14th Final consultation - Credits.

Conditions for subject completion

Full-time form (validity from: 1960/1961 Summer semester, validity until: 2013/2014 Summer 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 (30) 0
                Laboratory work Laboratory work 15  0
                Project Project 15  0
        Examination Examination 70 (70) 0
                Oral Oral examination 70  0
Mandatory attendence parzicipation:

Show history

Occurrence in study plans

Academic yearProgrammeField of studySpec.FormStudy language Tut. centreYearWSType of duty
2011/2012 (N2109) Metallurgical Engineering (2109T033) Foundry Technologies P Czech Ostrava 1 Compulsory study plan
2010/2011 (N2109) Metallurgical Engineering (2109T033) Foundry Technologies P Czech Ostrava 1 Compulsory study plan
2009/2010 (N2109) Metallurgical Engineering (2109T033) Foundry Technologies P Czech Ostrava 1 Compulsory study plan
2008/2009 (N2109) Metallurgical Engineering (2109T033) Foundry Technologies P Czech Ostrava 1 Compulsory study plan
2007/2008 (N2109) Metallurgical Engineering (2109T033) Foundry Technologies P Czech Ostrava 1 Compulsory study plan
2006/2007 (N2109) Metallurgical Engineering (2109T033) Foundry Technologies P Czech Ostrava 1 Compulsory study plan
2005/2006 (N2109) Metallurgical Engineering (2109T033) Foundry Technologies P Czech Ostrava 1 Compulsory study plan
2004/2005 (N2109) Metallurgical Engineering (2109T033) Foundry Technologies P Czech Ostrava 1 Compulsory study plan

Occurrence in special blocks

Block nameAcademic yearForm of studyStudy language YearWSType of blockBlock owner
FMMI_ECTS 2011/2012 Full-time Czech Compulsory 600 - Faculty of Materials Science and Technology - Dean's Office stu. block