Steel casting shop with a production capacity of 40,000 tons per year

In the section "Calculation and design part" a workshop was designed for the production of 40,000 tons of usable steel casting per year and the required amount of technological equipment of the workshop was calculated.
The section "Technological part" describes the technological process of obtaining the casting "Pulley of the generator drive" from the material Steel 35L GOST 977-88 and the calculations of the sprue system for obtaining this casting are given.
In the section "Technical and economic part" the calculation of production costs and the calculation of capital investments and the payback period of the project are made.
The section "Life safety and ecology" gives requirements for ensuring comfort in the workplace, describes protection from negative factors of the production environment, ensuring labor safety in the workplace, as well as measures to increase the sustainability of functioning in emergency situations.

Contents
Introduction 
Section 1 Calculation and design part 
1.1 Calculation of the production program  
1.2 Calculation of the capacity of the foundry 
1.3 Working hours of the workshop and time funds
1.4 General layout of the workshop and description of the adopted technological process 
1.4.1 Determination of the composition of the workshop. Selection of the type of industrial building, auxiliary and administrative buildings 
1.4.2 Office premises 
1.5 Calculation of the melting compartment 
1.5.1 Metal balance by smelted grades 
1.5.2 Selection of the type of melting unit 
1.5.3 Calculation of the number of melting units 
1.5.4 Charge calculation
1.6 Calculation of the molding and filling compartment 
1.6.1 Calculation of the production program of the department 
1.6.2 Calculation of the technological equipment of the molding department 
1.7 Calculation of the rod compartment 
1.7.1 Calculation of the production program of the department 
1.7.2 Calculation of the number of rod machines 
1.8 Thermal fringing compartment 
1.8.1 Thermal finish machining process
1.8.2 Calculation of the quantity of equipment 
1.9 Warehousing 
1.10 Workshop equipment 
1.11 Labour force calculation
Section 2 Technological part 
2.1 Choice of casting method
2.2 Selection of the position of the casting in the mold during the pouring and solidification period
2.3 Determining the surface of the mold connector
2.4 Determination of machining allowances, molding slopes, radius of curvature 
2.5 Graphic design of the casting 
2.6 Determination of the number and design of rods 
2.7 Composition and properties of the molding and rod mixture  
2.7.1 Forming mixture 
2.7.2 Composition of the rod mixture 
2.8 Development of the design of models, rod boxes and model plates 
2.9 Design development of the sprue-feeding system 
2.10 Determining the number of models on the stove
2.11 Choosing a molding method
2.12 Selection of equipment and description of the technological process of melting the alloy
2.13 Development of mold filling technology
2.14 Cooling of the casting in the mold. Equipment and technological process of stump knocking, cleaning, stripping, heat treatment of casting 
2.15 Development of a system for monitoring the technology and quality of castings 
2.16 Casting defects, preventive measures and corrections...  
2.17 Calculation of the sprue system 
2.18 Innovations in technology 
4 Life safety
4.1 Workplace comfort requirements
4.2 Protection against negative factors of the working environment 
4.2.1 Vibration 
4.2.2 Acoustic vibrations 
4.2.2.1Noise  
4.2.2.2Ultrasound 
4.2.2.3Infrasound 
4.2.3 Protection against electromagnetic fields and radiation 
4.2.4 Fire hazard protection
4.2.5 Protection against electric current 
4.3 Ensuring occupational safety in the workplace 
4.4 Measures to improve the sustainability of the enterprise in emergency situations 
4.5 Preparation and rescue operations in the event of a lesion  
4.6 Summary of BJD section
Conclusion 
Literature 

Generator drive pulley", according to nomenclature 740-1318160:
The casting is simple in design (the body of rotation with one central hole). The casting design ensures the assembly of molds. The mass of the part is small. The part is responsible for its intended purpose, the design of the part meets both the requirements of machining technology and the requirements of casting technology. To make a casting, one rod of a simple shape is required.
Taking into account the mass type of production, as well as the simple configuration, weight and dimensions of the casting, the accuracy class, we come to the conclusion that this casting is obtained by casting in sandy-clay forms. We use machine forming, we produce casting directly on the automatic molding line.
The adopted method of casting receives a high yield of suitable casting at relatively low costs, in the implementation of the technological process.

Conclusion
The aim of this project was to design a foundry for the production of 40,000 tons of usable castings from steel into one-time sand and clay forms.
The draft contains the following sections of the note:
Calculation and design of the foundry, including: 
(a) Calculation of the production programme;
b) calculation of the capacity of the foundry; 
c) mode of operation and time funds; 
d) calculation of the melting compartment;
e) calculation of the molding and filling compartment; 
(e) Calculation of the core compartment;
g) calculation of the heat-breaking compartment; 
h) labour force calculation.
All molding and charge materials are delivered to warehouses, where there should be minimal, but sufficient to ensure the normal operation of the workshop, their stocks.
Cast iron and steel scrap, ferroalloys arrive at warehouses in open wagons, on platforms and on machines. Unloading of scrap and ferroalloys with magnetic properties from wagons to bins is carried out by magnetic bridge cranes with a lifting capacity of 10 tons with lifting magnets that provide quick unloading of wagons.
Non-magnetic ferroalloys are unloaded with a grapple.
Limestone and other fluxes enter the warehouse in open gondola cars or on platforms, usually in crushed form; they are unloaded into the receiving pit, from which they are transferred by grapple to the bins for storage and then transported by grapple to the consumable bins for charging.
Refractory products arriving in bags and in containers or on pallets in open wagons are unloaded from the ramp by forklifts, which deliver them to storage sites and then to consumers. Refractory materials used for the preparation of lining mass (refractory clay, sand, refractory brick breakage, etc.) are stored in bins and transported to the preparation site  by a grapple.
Metal smelting is carried out in electric arc furnaces, from which the metal is transferred by means of transfer valves to the molding lines for pouring into the molds.
Production of molds, pouring, knocking is carried out on complexly automated molding lines.
In the workshop there are: one line with the dimensions of the opoks 1500x1100x400/400 with a capacity of 220 forms in and one line with the dimensions of the opoks 1100x750x300/300 with a capacity of 250 forms per hour.
The lines are equipped with casting plants for automatic and mechanized pouring of steel into molds.
The preparation of the molding mixture is carried out in mixed preparation plants separately for each line, which ensures that the molding lines are supplied with the mixture in the required quantity and quality. The mixing plant consists of high-performance continuous mixers, equipment for crushing, sieving, humidifying, cooling and loosening the molding mixture.
The manufacture of rods is provided on rod machines by the method of manufacturing by non-heated equipment. Rods removed from the rigging undergo stripping, splitting and drying after painting.
The rods are fed to the molding line through the PTC system and by loaders.
The casting knocked out of the mold together with the sprues enters the cooling gallery. Refrigerated castings are sent for shot blast cleaning. The bulk of the castings are cleaned in the pass-through shot chambers and drums.
Separation of sprues and sorting of castings takes place on plate and belt conveyors. Normalization of castings is carried out in pass-through thermal furnaces.
After the stresses are removed, the castings undergo secondary cleaning in batch cleaning drums and feed-through shot-throw chambers.
The technological chain closely connects all divisions of the workshop.
The smelting compartment is connected to the molding monorail system for dispensing liquid metal.
A single monorail system allows metal to be transferred from any dispensing furnace to any forming line. The rod compartment is connected to the molding compartment through the rod warehouse. The molding and pouring compartment is connected to the thermally chopped one through a cooling gallery and inter-operating casting warehouses.
Due to the large difference in the productivity of molding and cleaning units, the composition of the thermal cutting department includes inter-operating casting warehouses for the continuous shipment of finished products to the consumer.