Research & Development
UE "INSTITUTE BELNIILIT" over all years of its activity is engaged in development of the new progressive technologies and equipment for foundries of automobile and tractor building, agricultural engineering and enterprises of other economic branches.
VERTICAL STACK MOLDING
One of the significant project of BELNIILT is the technology of casting in vertical stack molds. The main feature of this technology is excellent rationality of mold design, in which there are a few levels of castings with weight of a few grams (piston rings) to 8 kgs on one riser. It ensures a possibility of considerable saving of labour, material and energy resources.
IMPACT & PRESS COMPACTING OF MOLDING MIXES
The technology of impact & press compacting of molding mixes also shows good results. The technology consists in a dynamic impact on molding mix with an air with net pressure up to 0.6 MPa. The technology has significant advantages as compared to conventional method of molds' making, such as high mold's density, availability to use mixes with advanced strength up to 2 kilogram-force/square centimetre, higher gas-permeability of mix, considerable saving of energy and metal.
CHILL MOLD CASTING
A great attention should be given to the accuracy of making casting blocks. For solution of this task the Institute developed single-, two- and multiposition machines for making shell molds with electric and gas heating as well as technology and equipment for manufacturing the castings in coated and uncoated chill molds.
UE 'INSTUTTE BELNIILIT' developed the technology and equipment for making castings by centrifugal method such as one-, two- and multiple rotor rotary machines with automated cycle of production of casting blocks of ferrous and non-ferrous metals.
TECHNOLOGY OF MAKING CORES
Core production plays an important role in obtaining castings of high quality. In domestic production structure labor content takes approximately 25% of total value of labour-output ratio when manufacturing castings.
The most wide spread process in foundries is engineering process of making cores in hot boxes and complex of automated core-making equipment based on this process. The range of products of BELNIILIT include machines for making cores with weight from a few grams to 100 kgs. They are equipped with covers, systems of elimination and neutralization of harmful gas release.
However for the last 20 years in developed countries the structure and nature of core-making has been fundamentally changed, that resulted in reducing of core making by heat drying and in changing of "hot" core making process for "cold". It is concerned with the fact, that the technology of making cores from cold-cured mixes has many advantages as compared to conventional "hot" process: it allows making complicated cores, the accuracy of cores and castings is much higher, the process of making and placing the cores into the mold may be fully automated. At that when using this technology the saving rate is considerable. It is resulted in essential savings on costs in foundries due to reduction of power consumption, core waste, increase of productivity of core making machines and so on.
Castings of nonferrous metals and alloys find more and more application in modern engineering and it makes higher demands for its production technology. First of all, it is necessary to ensure stable and high quality of castings providing low manufacturing cost.
One of the major process of production of aluminum casting is casting in permanent molds. i.e. chill mold casting. A kind of such process, which uses an advantage of basic types of gating system, is method of casting by self-pouring of mold, that is meld i poured in cups, which are parts of the mold, the mold is tilt from horizontal position in vertical position and melt goes slowly on riser (collecting channel) through feeders into the mold. Owing to tilting speed control it is able to fin an optimum ratio between solidification rate and rate of mold pouring. Thereby it is provided good infeed of crystallizable casting when pouring and filling of overlying layers. As a result the required volume of feeders considerable decreases, which are necessary now for feeding of upper parts of the casting.
SOLVING OF CASTING PROBLEMS
The problem of sponginess of castings is one of the critical problems in foundries for the last years, when share of using of secondary alloys in casting manufacture has increased sharply. Part of defective castings is 20 to 30 % and even 100% for some types.
One of the resource-saving technologies is technological process of soaking. It gives possibility not to remelt defective castings because of their nonhermeticity, but to repair them by soaking with special compositions, which permeate in pores of parts under certain conditions, then they solidify and clog the pores. This process is based on forcing vacuumization of parts in autoclave with subsequent supply of overpressure to sealant, which covers parts.
The equipment manufactured in UE "INSTITUTE BELNIILIT" can solve complex engineering problems almost in all fields of foundry on the up-to-date engineering level. It was developed a conception of stage-by-stage technical reequipment and it was implemented the project of programmed computing CAD system, which integrates automation equipped working places in interconnected net in engineering and design departments and department of computer-aided design.
Economic value of such CAD complex lies in the fact that it significantly enlarges the field of application of modern computer-aided systems and increases the level of automation in solving design and engineering problems.
When implementing new informational technologies of computer design in foundry equipment and technologies and technologies of making a high-quality casting block it appeared an opportunity at design stage to carry out sophisticated optimization problems of a set of variants, which imitate performance of designers and engineers in actual conditions of their work, to predict mechanical properties of design details, to predict appearance of different types of defects under unfavorable conditions, in conditions of influence of arising stresses, deformations, temperature and force fields.
Practice proved the effectiveness of using computer design aids by our specialists. Issue of drawing documentation has been speeded up considerably and its quality increased as well.
Three-dimensional simulation for development of sophisticated three-dimensional details and units together with program Compass-Graphic allow creating competitive foundry equipment.
UE "INSTITUTE BELNIILIT" has in its disposal highly qualified personnel of researchers, engineers and designers, good laboratory facilities. Specialists of the Institute on a high level will render you any assistance in development of technologies, designing the equipment and accessories, its manufacturing and production development of high-quality casting blocks.