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Procedia Manufacturing 22 (2018) 325–330 Procedia Manufacturing 00 (2017) 000–000 www.elsevier.com/locate/procedia 11th International Conference Interdisciplinarity in Engineering, INTER-ENG 2017, 5-6 October 2017, Tirgu-Mures, Romania 11th International Conference Interdisciplinarity in Engineering, INTER-ENG 2017, 5-6 October 2017, Tirgu-Mures, Romania

Studies of highly filled composite based on two-component organic binder stress state based inConference thermal stress Studies of highly filled composite on two-component organic Manufacturing Engineering Society International 2017, MESIC 2017, 28-30 June 2017, Vigo (Pontevedra), Spain binder stress state in thermal stress Ivan N. Erdakova, *, Vassily A. Ivanova, Vladislav A. Pashnyova, Pavel .V. Fekolina, b,c b a a, forDavydov a Walter , Danil a Vadim , Ralf Yu. Pimenov Costing models capacity optimization Industry 4.0:.V.Trade-off Ivan N. Erdakov *, Vassily A. Ivanov , Vladislav A.in Pashnyov , Pavel Fekolina, b,c b a Southused Ural Statecapacity University, 76, Lenin prospekt, 454080, Russia Vadim Davydov , Ralf Walter , Chelyabinsk, Danil Yu. Pimenov between and operational efficiency Walter+Bai AG , Industriestrasse 4, Löhningen, CH-8224, Switzerland P

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Abstract The article covers experimental studies of the physical and mechanical properties of composite material of flash heated core. The composite consists of quartz sand particles and a binder based on novolac phenol-formaldehyde resin cured with tertiary amine (coldAbstract The article process). covers experimental and industry mechanical properties ofincomposite material of flash heated The box-amine This materialstudies is usedofin the the physical metallurgical for mould cores the production of steel castings. Thecore. changes composite consists of quartz sand and athe binder based onsignificantly novolac phenol-formaldehyde resin cured with tertiary amineThe (coldof its strength properties during theparticles contact with melted metal impact the geometric accuracy of die cast parts. use Under theprocess). concept ofmaterial "Industry 4.0", processes becores pushed beanalysis increasingly interconnected, box-amine This is used theproduction metallurgical industryinfor mould in the to production ofsystem steel castings. changes of new dependence of the core modulus ofinelasticity on temperature thewill ProCAST engineering makes itThe possible to information based on a realthe time basis and, much more efficient. In this context, of its strength properties during contact with thenecessarily, melted metalcontraction significantly impact the geometric accuracy of die cast parts. The use simulate deformation processes with 2% deviation of nominal values compared to actual data capacity applied inoptimization the machineof newbeyond dependence of the core modulus of elasticity on temperature in the ProCAST analysis system makes itand possible to goes the traditional aim of capacity maximization, contributing alsoengineering for organization’s profitability value. building industry. simulate deformation processes and with 2% deviation of nominal contraction values suggest compared capacity to actual data applied in the machineIndeed, lean management continuous improvement approaches optimization instead of building industry. © 2018 The Authors. by Elsevier B.V. maximization. The Published study of capacity optimization and costing models is an important research topic that deserves Peer-review under responsibility of the scientific committeeperspectives. of the 11th International Interdisciplinarity in contributions from both the practical and theoretical This paperConference presents and discusses a mathematical © 2018 2018 The The Authors. Authors. Published Published by by Elsevier Elsevier B.V. B.V. © Engineering. model for capacity management on committee different costing models (ABCConference and TDABC). A generic in model has been Peer-review under responsibility of thebased scientific of the 11th International Interdisciplinarity Engineering. Peer-review under responsibility of the scientific committee of the 11th International Conference Interdisciplinarity in developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s Engineering. Keywords: cold-box-amine process; phenol-formaldehyde resin; flash heated core; hindered contraction alloy; thermal stress.

value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity optimization might hide operational inefficiency. Keywords: cold-box-amine process; phenol-formaldehyde resin; flash heated core; hindered contraction alloy; thermal stress. © 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference 2017. Keywords: Cost Models; ABC; TDABC; Capacity Management; Idle Capacity; Operational Efficiency

* Corresponding author. Tel.: +7-908-826-8619. 1.E-mail Introduction address: [email protected] * Corresponding author. Tel.: +7-908-826-8619. The cost of idle capacity is a fundamental for companies and their management of extreme importance E-mail address: [email protected] 2351-9789 © 2018 The Authors. Published by Elsevier information B.V. in modern under production systems. general, it is defined as unused capacity or production potential and can be measured Peer-review responsibility of theIn scientific committee of the 11th International Conference Interdisciplinarity in Engineering. 2351-9789 2018 The Authors. Published by Elsevier B.V.hours of manufacturing, etc. The management of the idle capacity in several©ways: tons of production, available Peer-review under Tel.: responsibility the761; scientific committee the 11th International Conference Interdisciplinarity in Engineering. * Paulo Afonso. +351 253of 510 fax: +351 253 604of741 E-mail address: [email protected]

2351-9789 © 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference 2017. 2351-9789 © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the scientific committee of the 11th International Conference Interdisciplinarity in Engineering. 10.1016/j.promfg.2018.03.049

Ivan N. Erdakov et al. / Procedia Manufacturing 22 (2018) 325–330 Ivan N. Erdakov et al. / Procedia Manufacturing 00 (2018) 333–338

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1. Introduction The inner cavities of castings are formed with moulding cores, which have the peculiarity of a fundamental change of strength properties from the capability to resist metallostatic pressure of melted metal to the core complete softening and removal of it’s residues from the die cast part. Highly-filled composites based on various organic binders are widely used for creating materials with special properties of this kind. For example, the cores are made of a cold hardening mixture cured during the cold-box-amine process and containing particles of quartz sand with two-component organic binder matrix in a ratio of 32 to 1.The composite matrix is a system of novolac phenolformaldehyde resin and polyisocyanate (mainly 4.4-methylene diphenyl diisocyanate) solutions cured with tertiary amines (triethylamine, dimethylisopropylamine, dimethyl-ethylamine, and trimethylamine) prepared according to TU 2257-028-18563945-2007. The publications covering studies of the composite properties describe the material advantages compared to similar systems [1, 2], research peculiarities of moulding cores production technologies [3], and ways of enhancing the mould- forming efficiency [4, 5], as well as investigating the impact of methods of adding gaseous curing agents to the mixture on the strength properties of the composite [6], and the addition of graphene to the phenolformaldehyde resin [7]. The publications in which the composite properties are defined during laser sintering of clad sand particles [8], and those, in which the thermomechanical parameters of cold-box-amine cores are found using photoelastic methods [9] should be mentioned separately. But none of the above works contain data on changes of composite strength properties during a contact with melted metal in the process of flash heating. Absence of these data can be explained by sophisticated mathematical descriptions of deformation processes in the core-die cast system and the problems of experimental measurements of physical and mechanical properties of samples heated using the thermal stress method. The complexity of alloy-hindered contraction calculations increases the time required for designing the casting equipment and making experimental castings to correct the model dimensions. In this respect, the research objective is to find a predicted pattern of changing the strength properties of the moulding core depending on its flash heating, and to define the parameters of the model deformation, which could be used in the solver of the ProCAST engineering analysis system [10 – 13]. Nomenclature σ Е ε εT δ d h Т T* t

compressive load (MPa) Young's modulus (modulus of plasticity, MPa) core compressive load deformation at a temperature of 20 0С core compressive load deformation at temperatures above 20 0С deviation in the core depth in compression (mm) diameter (mm) depth (mm) temperature (0С) arithmetic mean temperature of the core in ten points of an axial section (0С) the duration of the thermal effect on the core (s)

2. Experiment With regard to different types of deformation models [14 – 16], linear elastic dependence was selected to analyse the structure of the composite material (Fig. 1), cured with the cold-box-amine process.

σ = E (ε − εT ) , where σ represents the compressive load, (MPa); Е is Young’s modulus (modulus of plasticity, MPa);

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ε is the core compressive load deformation at the temperature of 20 0С; εT is the heated core deformation.

Fig. 1. Highly-filled composite material: The particle of silicon dioxide is coated with a covering 3 to 5 µm deep of two-component binder of novolac phenol-formaldehyde resin and polyisocyanate, cured with the tertiary amine.

As the linear elastic deformation model is characterized by the temperature dependence of changes in the modulus of plasticity, in order to define it experimentally, a cold hardening mixture core with diameter d = 5 mm, and depth h = 10 mm was used. Then the composite core was flash heated in a programmed muffle furnace produced by Nabertherm Gmbh, simulating its heating during the contact of melted metal with the mold box, and then destroyed in an INSTRON 5882 testing machine. The acceptable period of installation of the core heated in the furnace in the INSTRON equipment is defined on the diagrams as T* = f(t) (Fig. 2), where T* is the core arithmetic mean temperature at ten points of its axial section; and t is the duration of the core thermal effect The diagrams were plotted using the thermal problem data in ANSYS [17, 18]. A computer model included the areas of core heating in the furnace and in the melted metal. The temperature of the melted Hadfield steel was 1,450 0С, and the temperature in the furnace varied between 1,300, 1,350, 1,400, 1,450, and 1,500 0С. The calculations of the air-cooling of the core at room temperature were carried out individually.

Fig. 2. Characteristic curves of average temperature changes of highly-filled composite during flash heating: 1 – Furnace heating at 1,500 0С and air-cooling at 20 0С; 2 – furnace heating at 1,450 0С and air-cooling at 20 0С; 3 – furnace heating at 1,400 0С and air-cooling at 20 0С; 4 – furnace heating at 1,350 0С and air-cooling at 20 0С; 5 – furnace heating at 1,300 0С and air-cooling at 20 0С; 6 – Heating in Hadfield steel at 1,450 0С.


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The data in Fig. 2 show that correct measurement of the strength of the flash heated core is equal to heating in melted metal, and is obtained when installing the core in the furnace at 1,500 ºС for 60 seconds followed by destruction in the testing machine for 10 to15 seconds. Overheating of the core by 60 to 100 ºС prior to destruction requires updating of experimental data. This drawback of the measuring methods can be eliminated while reducing the time and material resources required for updating the data when samples are destroyed directly in the special chamber of a Walter+Bai AG measuring unit [19]. 3. Results and Discussion During the experiment, stress-strain diagrams of cores were obtained for various temperatures of melted metal. The stress-strain diagrams (Fig. 3a) helped to define the dependence of the cold hardening mixture modulus of elasticity on the core heating temperature (Fig.3b). The composite strain-stress state at the moment of destruction (Fig. 4, 5) was accessed in the DEFORM program [20, 21]. a

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Fig. 3. Dependence of changes of deformation of the cold-box-amine mixture core on compression load (a) and its modulus of elasticity (b) at different temperatures. a

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Fig. 4. Stress distribution during the core destruction for cross (a) and axial (b) sections at 20 0С.


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Fig. 5. Stress distribution during the core destruction for cross (a) and axial (b) sections at 1420 0С.

The data show that exposure of the composite to heating results in softening of the material matrix surface layers and lowering of its strength properties; thus, the load-bearing capacity of the entire core is reduced. During heating of the composite, its load capacity decreases linearly up to temperatures of 1,200 to 1,300 0С, and then tends dramatically toward zero due to the matrix softening in the entire part. During flash heating, the stress values of deformed composite are specifically re-distributed. Compared to the basic option when the material is kept at the room temperature, the stress transition range from 0.2 to 0.8 MPa is formed in the core surface layers parallel to the sample axis instead of forming in its ends. Due to the correction of experimental dependence (see Fig. 3b), the deviation of nominal contraction values obtained in the ProCAST system compared to actual steel casting data obtained in the OOO “ChTZ-Uraltrak” (Chelyabinsk) does not exceed 2 %. 4. Conclusions It should be noted that: • The deformation model of highly-filled composite based on phenol resin with silicon dioxide particles (core mixture cured during the cold-box-amine process) has linear elastic characteristics and is defined by the modulus of elasticity changes versus temperature; • The composite’s modulus of elasticity value decreases linearly up to the temperature 1,200 to 1,300 0С, and then tends dramatically toward zero due to softening of the matrix with organic binder; • Due to the thermal destruction of the resin and loss of the material bearing capacity, in the core surface layers the strain-hardening area 0.2 to 0.8 MPa was formed along the compression load direction; • The deviation of nominal contraction values compared to actual steel-casting-hindered contraction data does not exceed 2 %. 5. Acknowledgments The authors thank Mary Ilieva, Ckelyabinsk, Russia ([email protected]) for a preliminary translation of the article in English.

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The research was carried out under government contract of Russian Federation no. 03691000176140000750041893-01 of 19 June 2014 within the South Ural State University Development Program from 2010 to 2019. The research was carried out within the South Ural State University Project 5-100 from 2016 to 2020 aimed to increase the competitiveness of leading Russian universities among the world research and educational centers. The work was supported by Act 211 Government of the Russian Federation, contract Nr 02.A03.21.0011. References [1] G.W. Ritter, Phenolics-oldies but goodies, Assembly 51(11) (2008) 10. [2] Y.N. Budanov, The choice of techniques for steel castings manufacturing the railcar wheels, Litejnoe Proizvodstvo (10) (2004) 15–21. [3] G.I. Bobryakov, The technical engineering core making center, Litejnoe Proizvodstvo (10) (1997) 8–9. [4] J. Zych, L. Jamrozowicz, Advancement of the hardening front in forms and cores made of quickly bonding composites - Ultrasonic analyses, Arch. Metall. Mater. 55(3) (2010) 963–968. [5] J. Archibald, J. Kroker, High efficiency cold box processes-technology focused on business goals, Int. J. Metalcast. 7(2) (2013) 51–59. [6] I. Aguirre, A. Velasco, J. Talamantes, R. Colas, Effect of graphene used as filler in organic binder during the cold box process, 70th World Foundry Congress 2012;WFC 2012 (2012) 268–273. [7] J. Zych, Pulsating gas dosage in the moulding sands hardening process in the cold-box technology, Arch. Metall. Mater. 58(3) (2013) 837– 840. http://dx.doi.org/10.2478/amm-2013-0082 [8] F.R. Liu, J.J. Zhao, Q. Zhang, C. He, J.M.Chen, Processing and characterizations of 2%PF/silica sand core-shell composite powders by selective laser sintering with a higher transmittance fiber laser, Int. J. Mach. Tool. Manuf. 60 (2012) 52–58. http://dx.doi.org/10.1016/j.ijmachtools.2012.05.003 [9] I. Caylak, R. Mahnken, Thermomechanical characterisation of cold box sand including optical measurements, Int. J. Cast Metal. Res.23(3) (2010) 176–184. http://dx.doi.org/10.1179/174313309X451261 [10] A.D. Abdullin, New capabilities of software package ProCAST 2011 for modeling foundry operations, Metallurgist 56(5-6) (2012) 323–328. http://dx.doi.org/10.1007/s11015-012-9578-8 [11] Z. Yang, J. Han, S. Cui, S.B. Kang, J.M. Lee, Solidification simulation of a SiCp/Al disk brake casting, J. Ceram. Process. Res. 7(4) (2006) 363–366. [12] J. Zhang, Z.J. He, K.R. Zhang, C.M. Hu, F.J. Zhang, L. Xi, Technique and numerical simulation of investment casting for TiB2/A356 diversion impeller, Zhuzao/Foundry 64(7) (2015) 636–638. [13] D. Broek, The Practical Use of Fracture Mechanics, Kluwer Academic Publishers (1988) 532. [14] A.T. Zehnder, Fracture Mechanics Series Editors Friedrich Pfeiffer, Peter Wriggers. Springer London Dordrecht Heidelberg New York, 2012, p. 234. ISBN:978-94-007-2594-2, e-ISBN:978-94-007-2595-9 (Lecture Notes in Applied and Computational Mechanics. Volume 62) [15] I.A. Birger, Y.G. Panovko, Strength, stability, vibration. Handbook in three volumes. vol. 1, 2. Moscow: Mashinostroenie, 1968, p. 355. [16] L.I. Sedov, Continuum mechanics. Volume 1. Moscow: Mashinostroenie 1970, p. 492. [17] V.A. Pashnyov, D.Yu. Pimenov, Stress analysis of a three-layer metal composite system of bearing assemblies during grinding, Mech. Compos. Mater. 51(1) (2015) 109–128. http://dx.doi.org/10.1007/s11029-015-9478-7 [18] D.Yu. Pimenov, V.I. Guzeev, Mathematical model of plowing forces to account for flank wear using FME modeling for orthogonal cutting scheme, Int. J. Adv. Manuf. Technol. 89(9) (2017) 3149–3159. http://dx.doi.org/10.1007/s00170-016-9216-x [19] http://www.walterbai.com [20] M.C. Manea, D. Timofte, S. Velicu, Prediction of forces and damage at forming sheet on multipoint die, Appl. Mech. Mater. 656 (2014) 215–222. http://dx.doi.org/10.4028/www.scientific.net/AMM.656.215 [21] M. Kukuryk, Analysis of deformation and damage evolution in hot elongation forging, Arch. Metall. Mater. 57(2) (2012) 417–424. http://dx.doi.org/10.2478/v10172-012-0041-4.