Steel shop project with a capacity of 16 thousand tons / year

Contents

Introduction

1. Development of workshop design

1.1 Justification of general project decisions

1.2 Smelting compartment

1.3 Molding compartment

1.4 Rod compartment

1.5 Mixing compartment

1.6 Description of the foundry

2. Development of production process of "Earring" casting

2.1 Justification of moulding method

2.2 Justification of part position in mold during filling

2.3 Justification of Shape and Model Parting Surface Selection

2.4 Substantiation of shrinkage and machining allowances, slopes, fillets

2.5 Definition of structures and dimensions of rod signs

2.6 Runner System

2.6.1 Runner system elements and their purpose

2.6.2 Runner System Type Selection

2.6.3 Selection of metal supply point to casting

2.6.4 Runner System Calculation

2.7 Justification of the applied tooling

2.8 Selection of moulding and rod mixtures

3. Design development of press unit

3.1 Physical essence of mixture compaction process during manufacturing

moulds by pressing

3.2 General layout of press molding machines

3.3 Press Mechanisms

3.4 General description of the calculated press unit by model 5833G type

3.4.1 Device and operation

3.4.2 Control diagram

3.5 Advantages and disadvantages

3.6 Calculation of press machine

3.6.1 Calculation of lever pressing mechanism

3.6.2 Calculation of indicator diagrams

3.6.3 Calculation of the frame

4. Occupational safety

4.1 Analysis of hazardous and harmful production factors of the foundry

4.2 Measures to reduce hazardous and harmful industrial factors

4.2.1 Calculation of artificial lighting

4.3 Requirements for safe organization of operations on the press unit

4.4 Fire safety measures of the shop

5. Industrial ecology

5.1 Analysis of state of environment of KazTehStalProm LLP

5.2 Calculation of emissions of harmful substances during steel casting

5.3 Waste disposal and disposal

6. Project Feasibility Study

6.1 Design basis for a dedicated steel casting shop with a capacity of 16 thousand tons per year

6.2 Selection of foundry equipment

6.2.1 Smelting compartment

6.2.2 Molding equipment

6.2.3 Rod compartment

6.2.4 Mixing compartment

6.2.5 Heat tube compartment

6.2.6 Capital investments in workshop equipment

6.2.7 Capital investments in tooling, production tools and equipment

6.2.8 Calculation of capital investments in the production building of the designed workshop

6.3 Calculation of the number of production workers by workplaces based on the maintenance standards for units

6.3.1 ETS and calculation of weighted average tariff factor for foundry workers

6.3.2 Number of auxiliary workers

6.3.3 Determining the number and composition of employees (organizational structure of the workshop management)

6.4 Calculation of the wage fund

6.4.1 Calculation of the wage fund for industrial workers

6.4.2 Calculation of social, individual income tax deductions and pension deductions

6.4.3 Calculation of the wage fund for auxiliary workers

6.4.4 Calculation of social, individual income deductions

taxes and pension contributions

6.5 Calculation of energy costs for non-technological purposes

6.5.1 Energy consumption for non-technological purposes

6.6 Calculation of cost of casting production

6.6.1 Calculation of the cost of liquid steel

6.7 Calculation of cost-effectiveness of capital investments

List of sources used

Applications

Introduction

The importance of foundry for the national economy and primarily for mechanical engineering is extremely great. Foundry is the main procurement base that determines the possibilities for further development of the engineering industries. The method of producing shaped blanks by pouring metal into molds is still the simplest and most accessible.

Castings have significant advantages over other types of billets. The choice of the type of workpieces for machine-building parts is mainly due to different technical requirements for their quality.

When designing foundries and plants, special attention should be paid to improving the quality of castings. As a result of automation of cutting processing, the requirements for geometric accuracy of cast blanks increased. The evaluation of the design of machines by specific weight per unit of power determined the tendency to obtain thin-walled castings and a decrease in the specific weight of cast parts from the total weight of the equipment.

With an improvement in the appearance, and therefore with an increase in the competitiveness of products, the requirements for surface quality and appearance of castings increased.

There was an orientation towards the use of various charge materials in smelting departments. The use of preheating of the charge is widespread. Reduction in gas content can be achieved by smelting steel in new smelters such as induction vacuum furnaces.

The trend of improving the system of planning and reporting on foundry production was determined, aimed at increasing the production of castings in pieces, and not in tons. To reduce the metal consumption of products, there has been an increase in the production of HF molds, pipes, tubing and castings in the automotive industry. The production of castings from aluminum alloys will be increased.

The most important modern problem of foundry is the automation of mold pouring. This task is already being solved for both cast iron and steel castings, this will increase the possibility of using automatic molding lines. The use of wet cleaning in mixing and cleaning rooms, as well as the use of dust collection vacuum systems, is expanding. All waste should be separated. Granulation of slags for subsequent separation is provided. The requirements for working conditions have increased, to improve the protection of the surrounding atmosphere and adjacent water basins.

Development of workshop design

1.1 Justification of general project decisions

According to a task the project of the shop of mass production of the 16,000 tons per year steel casting in the conditions of KazTehStalProm LLP has to be designed.

KazTehStalProm LLP makes steel and iron casting of industrial function and also decorative casting in sandy forms, castings weighing from 0.5 kg to 5 tons, machine and manual molding.

Due to the large number of castings of the base shop, the production capacity is calculated according to the given program when fifteen representatives are included in it.

The production building of the designed workshop is located in a building with dimensions of 72000x144000 m2 and height of 10.5 m.

The main activity of the enterprise is steel casting.

The mode of operation is two-shift for 8 hours/shift, 254 days per year. The planned maximum capacity of 16,000 tons of suitable casting per year. The manufacturing process consists of the following stages:

- reception, storage and preparation of charge materials;

- preparation of moulding and rod compositions;

- manufacture of molds and rods;

- steel melting;

- casting, cooling and knocking out of castings;

- cleaning of casting;

- thermal treatment of casting;

- acceptance of finished products and correction of casting defects;

- processing of waste of own production (return of own production, scrap).