RATIONALIZATION OF PRODUCTION OF SHAPED INSERTS FOR ROTOR CASTING

This paper summary is based on the article ['RATIONALIZATION OF PRODUCTION OF SHAPED INSERTS FOR ROTOR CASTING'] presented at the ['MM SCIENCE JOURNAL']

Figure 1. Solved shaped inserts [Dostal 2012]

Table 1. Material for the production of shaped inserts [Lentus 2007]

1. Overview:

Title: RATIONALIZATION OF PRODUCTION OF SHAPED INSERTS FOR ROTOR CASTING
Author: PAVEL DOSTAL, MAREK SADILEK
Publication Year: 2021
Publishing Journal/Academic Society: MM SCIENCE JOURNAL
Keywords: Rationalization, die casting, shaped inserts, casting, milling

2. Research Background:

Background of the Research Topic:

Shaped inserts are integral components in rotor casting, produced in pairs (front and rear) for various axial heights (100, 112, 132, and 160). They are inserted into a die-casting apparatus for high-pressure aluminum casting. The inserts can be divided into fixed and movable parts. [Dostal 2012]

Status of Existing Research:

Existing production methods for molds primarily involve machining (milling) or electroerosive machining of tool steels. There is ongoing pressure to reduce machine times and production costs, leading to the development of methods like high-speed machining (HSC), machining of hard materials, and 5-axis machining. [Grov 2005]

Necessity of the Research:

The rationalization of production is crucial for improving company competitiveness. This involves exploring new technologies that offer economic benefits and improved working conditions.

3. Research Purpose and Research Questions:

Research Purpose:

The main purpose is to propose and evaluate a new technological process for producing shaped inserts, comparing it with the existing process.

Key Research:

The key research is to provide a technical and economic evaluation of the proposed solution.

4. Research Methodology

Research Design:

The research involves a descriptive analysis of existing technology, followed by the design and evaluation of a new technological process.

Data Collection And Analysis Method:

The research compares existing and proposed processes, focusing on parameters like adjustment times, production times, and production costs.

Research Subjects and Scope:

The research focuses on shaped inserts for rotor casting, specifically those made of medium-alloy chromium-molybdenum tool steel (CSN 19 552.3). The example used is a front insert of axial height 160. [Dostal 2012]

5. Main Research Results:

Key Research Results:

The proposed technology, primarily utilizing milling instead of electro-erosive gouging, significantly reduces production times and costs. For example, for the 160 axial height front insert, the adjustment time is reduced by 94 minutes, and the processing time is reduced by 1231 minutes.

Chart 1. Technology comparison [Dostal 2012]

Chart 2. Technical comparison [Dostal 2012]

Figure Name List:

Figure 1. Solved shaped inserts [Dostal 2012]
Figure 2. Shaped insert model [Dostal 2012]
Figure 3. MCFV 1260 machine [TAJMAC-ZPS 2012]
Table 1. Material for the production of shaped inserts [Lentus 2007]
Table 2. General technological process of production of shaped insert [Havranek 2010]
Table 3. General proposed technological procedure of the insert [Dostal 2012]
Table 4. Comparison of technologies of all axial heights [Dostal 2012]
Chart 1. Technology comparison [Dostal 2012]
Chart 2. Technical comparison [Dostal 2012]

6. Conclusion:

Summary of Main Results:

The new technological process, mainly using a TAJMAC MCFV 1260 4-axis milling machine, significantly reduces production time and costs compared to the existing process that relies heavily on electro-erosive machining. The total time saving for all shaped inserts (100-160) is 3995 minutes, and the total cost savings are CZK 27372.

Limitations of the Research

The research is limited by the available machinery in the workshop, restricting comparisons to electro-erosive gouging and milling. Other potential methods could not be verified.

7. Future Follow-up Research:

Directions for Follow-up Research: Further research could explore and compare other manufacturing methods for shaped inserts, such as electroplating and electrospark machining.
Areas Requiring Further Exploration: A more in-depth analysis of the surface quality and resulting accuracy of different machining methods could be beneficial.

8. References:

[Alam] ALAM, M.R., K.S. LEE, M. RAHMAN, Y.F. ZHANG, Y.D. LI a K.S. SANKARAN. COMPARATIVE STUDY OF HSM AND EDM IN INJECTION MOULD MANUFACTURING. Initiatives of Precision Engineering at the Beginning of a Millennium. Boston: Springer, 324-328. DOI: https://doi.org/10.1007/0-306-47000-4_63. ISSN 978-0-306-47000-4.
[Dostal 2012] DOSTAL, P. Rationalization of Shaped Setting Block Production for Moulding Rotors AH100-160: Master Thesis. Ostrava: VSB - Technical University of Ostrava, Faculty of Mechanical Engineering, Department of machining, assembly and engineering metrology, 2016, 71 p. Thesis head: Sadilek, M.
[Grov 2005] Grov, N.: Aluminum die casting options - use of this technology in the boundary region. Foundry No. 2-3, 2005, pp. 95-101
[Havranek 2010] HAVRANEK, Radek (ed.). General technological procedures of shaped inserts from Siemens s.r.o. Mohelnice, 2010.
[Lentus 2007] 19 552.3. In: Lentus [online]. Dolni Bousov: LENTUS spol. s r.o., 2007 [cit. 2016-04-14]. Available from: http://www.lentus-ocel.cz/tridy-oceli/n-19-5523.htm
[Oettle 2005] OETTLE, Matthias. Hard milling in tool and molds. MM: Industrial spectrum. 2005, p. 30.
[Svoboda 2016] Center lathe. In: Stroje Svoboda s.r.o. [online]. Blansko: strojesvoboda.cz, 2016 [cit. 2016-03-18]. Available from: http://strojesvoboda.cz/katalog.php?page=DETAIL&katalog=Stroje/Soustruh&key=&id=9344&ids=9360&o=1
[TAJMAC-ZPS 2012] MCFV 1260 Vertical machining center. TAJMAC-ZPS, a.s. [online]. Malenovice: TAJMAC-ZPS, a.s., 2012 [cit. 2016-04-01]. Available from: http://www.tajmac- zps.cz/en/MCFV-1260
[Zelinski 2000] ZELINSKI, Peter. EDM vs. Milling In Die/Mold Machining. Modern Machine Shop [online]. 2000 [cit. 2018-07-24]. Available from: https://www.mmsonline.com/articles/edm-vs-milling-in- diemold-machining

9. Copyright:

This material is "PAVEL DOSTAL, MAREK SADILEK"'s paper: Based on "RATIONALIZATION OF PRODUCTION OF SHAPED INSERTS FOR ROTOR CASTING".
Paper Source: DOI: 10.17973/MMSJ.2021_10_2021088

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Tags: Aluminum Casting; ,Aluminum Die casting; ,CAD; ,Die casting; ,Efficiency