International Journal of Mechanical and Production

Engineering Research and Development (IJMPERD)

ISSN(P): 2249–6890; ISSN(E): 2249–8001
Vol. 10, Issue 1, Feb 2020, 657–664
© TJPRC Pvt. Ltd.

FOUNDRY DESIGN SCHEME

VLADIMIR VLADIMIROVICH DESNITSKY1, LYUDMILA VLADIMIROVNA DESNITSKAYA2

& IGOR ALEKSANDROVICH MATVEEV3
1Professor, Higher School of Physics and Materials Technology, Peter the Great
St. Petersburg Polytechnic University, Russia
2Associate Professor, Higher School of Physics and Materials Technology, Peter the Great
St. Petersburg Polytechnic University, Russia
3Associate Professor, Graduate School of Physics and Materials Technology, Peter the Great
St. Petersburg Polytechnic University, Russia
ABSTRACT

A modern foundry is a complex production and technological system. It is necessary to use system analysis and
mathematical methods to significantly improve its performance. UML (Unified Modeling Language) is one of the tools
for its implementation. To increase the competitiveness of the enterprise, the work of the workshop must be optimized
according to a number of parameters: the maximum use of production capacities, the selection of rational technology,

Original Article
the improvement of the design and manufacturability of the cast part, and the minimization of the likelihood of defects in
castings; all this requires a comprehensive system analysis. The article discusses an example of a system analysis of the
operation of a steel casting workshop using the vacuum-film molding method for equipment loading and elimination of
casting defects. For a more complete analysis of the work of the workshop, it is necessary to draw up several dozen
diagrams, examples of which are given in the article.

KEYWORDS: Vacuum-Film Molding, System Analysis of the Foundry, Technological Systems of the Foundry,
Optimization of the Foundry & Lean Manufacturing

Received: Nov 09, 2019; Accepted: Nov 29, 2019; Published: Feb 06, 2020; Paper Id.: IJMPERDFEB202053

INTRODUCTION

A modern foundry is a complex production and technological system. To significantly improve its work, it is
necessary to use system analysis and mathematical methods. UML (Unified Modeling Language) is one of the tools
for its implementation. To increase the competitiveness of the enterprise, the work of the workshop must be
optimized according to a number of parameters: the maximum use of production capacities, the selection of rational
technology, the improvement of the design and manufacturability of the cast part, and the minimization of the
likelihood of defects in castings[2]; all this requires a comprehensive system analysis.

METHODOLOGY

Modeling of production processes involves a complete accounting of all operations. Finding this rational set is
impossible without an accurate model using modern means. The constructed model provides the best technical
design solution, and not just perform an economic task [1]. The technical solution takes into account the quality
of cast billets, issues of equipment operation stability, its maintainability, the ability to update technical units and
others.

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658 Vladimir Vladimirovich Desnitsky, Lyudmila Vladimirovna Desnitskaya
& Igor Aleksandrovich Matveev

The most modern and productive is considered an object-oriented approach, which meets the needs of
development to the greatest extent [7].

RESULTS AND DISCUSSIONS

When using lean manufacturing ideas, the workshop provides a multi-threaded scheme of the molding process, and the
process should be considered taking into account the optimization of technological flows and routes.

Despite the effective technological process, it is possible to constantly improve it by reducing the inter operational
time, improving transport operations, reducing stocks of materials, etc. [4].

A search tool for this is the construction of domain model diagrams in the UML language. The process of
constructing diagrams is the process of finding a rational construction of a production system. Moving an object from one
workplace to another is clearly visible, and the required technological operations are performed on each of them. This form
of description of the production process opens up the possibility of finding unsuccessful combinations of technological
operations, transport operations and other reasons that reduce production efficiency.

The construction begins with diagrams of use cases, where a list of tasks of the system in question is declared.
The following business process participants were identified for the system: master, operator, etc. (Figure 2). In this case,
the diagrams must be performed jointly - the control system and the model of the workshop.

A well-designed model makes it possible to freely move from the general idea of the system to the individual
details of the implementation of its components.

Workshop modeling lays the foundation for building an economic management information system. The success
or failure of projects to create integrated corporate information systems depends on how adequate the production model is.
The vacuum casting technology provides, compared with casting in sand-clay molds or molds from cold-hardening
mixtures, a 15-20% reduction in the laboriousness of casting manufacturing due to reduction of rejects, mixing and
finishing operations [3]. In addition, when casting by vacuum-film molding, the environmental performance of castings is
significantly improved (Figure 1).

The most common defects in vacuum molding are: porosity, burning, blockages (inclusions of molding sand or
synthetic film) [6]. These defects are also characteristic of traditional casting methods.

Slag, oxide inclusions and under filling are not more common in a vacuum process than in traditional castings.
The most typical types of defects and methods for their elimination are described below (Table 1).

Porosity occurs most often on the surface or near the surface of thin-walled castings. This is due to the fact that
the liquid metal filling the mold cavity is exposed to excessive gas pressure, under the influence of which a surface crust
quickly forms on the casting. In the thin-walled parts of the casting, gases released from the mold do not have time to leave
and form surface or subcortical porosity [5,11]. The thicker the walls of the castings, the less porosity arises due to the
slower solidification [13].

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Foundry Design Scheme 659

Figure 1: Vacuum Molding Line.

Mold Making

The molding machine consists of:

 4-position carousel (B18)

o flask transfer station

o station filling sand and pulling the coating film

o flask transfer station

o rotary table transfer station

 6-position rotary table (B11):

o E- station transfer models with a lift table

o F- model training station

o G- model film tensioning station

o HI-station model training

o J-station paint application

 2-position turntable for models (B15):

o D + F- paint drying stations

Table 1: Defects and Causes

Defects and Their Causes
1. Gas porosity and shells.
1.1. Gas evolution from metal due to
violation of smelting technology.
1.2. Low pouring temperature, intermittent
pouring.
1.3. Low pouring speed.
Remedies
1.1. The smelting technology should ensure the
lowest possible gas saturation of the melt.
1.2. Raise the pouring temperature, fill with a
continuous stream, and fill through the sprue bowl.
1.3. To increase the pouring speed, when pouring
flat castings, it is recommended to set the mold with

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660
1.4. Small cross section and incorrect
position of the outlet.
1.5. There is no escape of gases from the
rods.
1.6. Insufficient drying of the refractory
coating.
1.7. Large thickness of the synthetic film.
1.8. Insufficient amount of rarefaction in the
volume of sand during pouring.
2. Sand or slag inclusions (blockages).
2.1. The erosion of the riser or gate system
elements.
2.2. High pouring speed.
2.3. Uneven coloring of the surface of the
form.
2.4. Shedding of molding sand due to low
packing density or insufficient rarefaction.
3. Inclusion of pieces of synthetic film.
3.1. Insufficient adhesion of the film to the
surface of the form, its separation during the
pouring process.
3.2. Lowdensitypadding
4. Theburn.
4.1. Used molding sand of large fractions.
4.2. Lack of refractory coating on the film
surface.
4.3. Low density padding forms.
4.4. Insufficient refractoriness of the
molding material due to the presence of
impurities (iron oxides, etc.).
4.5. Insufficient heat resistance of the
refractory coating.
4.6. Local overheating of massive casting
units
5. Growths (a defect characteristic only for
vacuum molding):
5.1. Damage to filters through which air is
pumped out and sand is sucked into the
vacuum system.
5.2. Damage to the film when facing or
removing the model.
6. Dents.
6.1. Oxidation of the surface of the casting
with air pumped for a long time after
pouring the metal through the gaps between
the casting and the mold.
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Vladimir Vladimirovich Desnitsky, Lyudmila Vladimirovna Desnitskaya
& Igor Aleksandrovich Matveev
an inclination.
1.4. The outlet cross section should be 2-3 times the
bottleneck of the gate system.
The flash should ensure unhindered gas exchange of
the mold cavity with the atmosphere.
1.5. The design of the mold should provide a
reliable exit of gases from the rods.
1.6. Control the quality of coating drying.
1.7. Reduce the thickness of the applied film.
1.8. To increase the amount of vacuum due to filter
pipes (their location and quantity).
2.1. The design of the gate system should ensure its
full filling during pouring, eliminating the
possibility of air leakage and the destruction of
elements by a metal jet.
2.2. Reduce fill speed.
2.3. Control the quality of the coating, avoiding the
appearance of unpainted surfaces, especially when
using sands of large fractions.
2.4. Increase the packing density, control the
amount of vacuum during the pouring process.
3.1. Use “sevilen” type films at the optimum heating
temperature, dry the refractory coating at the
optimum temperature, and the coating should be of
the optimum thickness.
3.2. Monitor packing density over the entire surface
of the mold cavity.
4.1. Use molding sand grades K01 and K0063.
4.2. Apply a uniform layer of refractory coating to
the film with a thickness of at least 150... 200
microns
4.3. Provide the required packing density and the
required vacuum value.
4.4. Check the chemical composition of the sand.
4.5. Use a coating with high refractoriness.
4.6. Change the design of the gate system, use
refrigerators.
5.1. Check the condition of the filters before
molding.
5.2. Check the surface condition of the molds before
assembling them: if cavities appear on the working
surface, the molds must be rejected.
6.1. Turn off the vacuum system after 8... 12
minutes after filling.
6.2. After pouring massive castings, fill up the riser,
profit and sand blasting.
NAAS Rating: 3.11
Foundry Design Scheme 661

Figure 2: Use Case Diagram Fragment.

Figure 3: Formation Sequence Chart.

In this case, the following notation is used:

 A – molder

 B - frame for heating the film1,

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662 Vladimir Vladimirovich Desnitsky, Lyudmila Vladimirovna Desnitskaya
& Igor Aleksandrovich Matveev

 C2 - frame for heating the film 2,

 D - molding table for the lower flask,

 F - molding table for the lower flask 2,

 G - the place under the filling device,

 H - the place to assemble the mold, I - molder 2,

 J - frame for heating the film 3,

 K - frame for heating the film 4,

 L - the place under the filling device 2,

 M - place for the assembly of form 2,

 N - place on a roller conveyor,

 O- retention of the filled flask over the knockout device for cleaning from film residues,

 P - knockout flask.

A large number of movements and the simultaneous accumulation of finished forms at the knockout position can
be seen from the diagram (Figure 3). Thus, it is immediately possible to significantly increase the efficiency of a workshop
section with minimal financial costs.

A complete set of diagrams is used to build a production management system, without which it is impossible to
ensure the competitiveness of the enterprise.

However, we can distinguish a number of stages that determine a rational design scheme:

 the formulation of the technical task should be performed by a system analyst in the UML language, where, based
on graph theory, diagrams are compiled reflecting the conceptual basis of the project. Together with the customer,
the study and preparation of technical specifications for the creation of a foundry are being carried out.

 analysis of the nomenclature of castings and the development of technological processes for their manufacture.

 development of pre-project proposals and a feasibility study for the production being created. Advanced
enterprises try to constantly search for hidden opportunities and resources, analyze complex problems. The main
goal of the analysis is to find a system or a system element that has always influenced the result, but was
previously not controlled [12]. Maybe this element was in sight, but it was underestimated. The main task is to
find resources and tools for managing this system at the expense of internal resources [14].

With the help of the system, all the activities that are carried out by the enterprise are visualized: you can see what
and how is happening on the line at any given time.

The task of production analysis corresponding to the precedent of mold manufacturing begins with the
introduction of a list of operations and their durations on the program screen [9].

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Foundry Design Scheme 663

CONCLUSIONS

To conduct a systematic analysis of the operation of the foundry, we conditionally divide it into several
hierarchical levels. To comprehensively optimize the operation of the foundry, it is necessary to analyze the work
and find the best solutions for the mold casting section, casting mold assembly section, analyze several options for
molding mixtures, 2-3 types of steel grades, work with improving the casting design, test several heat treatment
options [8, 10]. For a more complete analysis of the work of the workshop, it is necessary to draw up several
dozen diagrams, examples of which are given in the article. The totality of such diagrams will allow visu alizing
the work of the workshop as a single system.

REFERENCES

1. Desnitsky V.V., Desnitskaya L.V., Matveev I.A. Problems of increasing economic efficiency in casting production simulation.
Proceedings of the 34th International Business Information Management Association Conference - Vision 2020: Sustainable
Economic Development and Application of Innovation Management from Regional expansion to Global Growth, 13-14
November 2019, Madrid, Spain. In Press.
2. Ol'khovik, E.O., Desnitskii, V.V., Molchanyuk, R.A. Interaction between casting and mold during solidification. Steel in
Translation, 2007, No. 37 (5), pp. 422-424.
3. Glukhov P. V., Valeev I. E., Shaparev A. V. Features of the technology of vacuum-film molding for foundry. Scientific-
methodical electronic journal "Concept", 2015, Vol. 13, P. 2241–2245. Available at: http://e-
koncept.ru/2015/85449.htm.

4. Shrivastava, A. A Study on Application of Lean Techniques in Indian IT Industry.

5. Ol'khovik E.O., Desnitskaya L.V. Prediction of structures of castings. Izvestiya Ferrous Metallurgy, 2004, Issue 11, pp. 49-53.
6. Feklin N. D. Foundry compatibility analysis. Vacuum film molding. ITB "Cast ing of Ukraine", 2019, No. 7 (227),
p.2-7.

7. Singh, K., & Deokar, A. (2018). Effects of 5S Implementation on Performance of Organization. International Journal of
Business and General Management (IJBGM), 7(2), 1-14.

8. Kyu-Sik Park. High Strength Steels in the Scope of Structural Applications. SEAISI Quarterly, 2019, Vol. 48, No. 2.

9. Martin Fowler. UML The basics. Third edition. Quick Guide to the Standard Object Modeling Language, Publisher: Symbol-
Plus, 2013

10. Vader, M. Lean production tools: A mini-guide on the implementation of lean production methods. Moscow: Alpina Publisher,
2008, p. 128.

11. Dryzhevskij, M.A., Desnitskij, V.V., Shandyba, G.A., Matveev, I.A. Prediction of mechanical properties in a steel casting
during technical process design. Litejnoe Proizvodstvo, 1996 (4), pp. 31-32.
12. Deshmukh, R. A., & Hiremath, R. Decision Making with Analytical Hierarchy Process for Selection of Furnace for Foundry
Industry.

13. Desnitskij, V.V., Nazarov, V.I., Gritsenko, A.Ya. Designing technology of formation of large steel castings. Litejnoe
Proizvodstvo, 1992 (6), pp.28-29.
14. Masaaki I. Kaizen: the key to the success of Japanese companies. Moscow, Alpin Business Books, 2007.

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664 Vladimir Vladimirovich Desnitsky, Lyudmila Vladimirovna Desnitskaya
& Igor Aleksandrovich Matveev

AUTHORS PROFILE

Vladimir Vladimirovich Desnitsky, did doctorate in Technical Science. Now working as Professor in Higher School of
Physics and Materials Technology at Peter the Great St. Petersburg Polytechnic University, Russia

Lyudmila Vladimirovna Desnitskaya, did PhD in Technical Science. Now working as Associate Professor in Higher
School of Physics and Materials Technology at Peter the Great St. Petersburg Polytechnic University, Russia

Igor Aleksandrovich Matveev, did PhD in Technical Science. Now working as Associate Professor in Graduate School of
Physics and Materials Technology, Peter the Great St. Petersburg Polytechnic University, Russia

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