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Open access

R. Dańko, M. Holtzer and J. Dańko

Abstract

The after reclamation dusts originated from various foundry plants, applying moulding sands with organic binding agents, mostly resins, are characterised by different properties in dependence of the used binders, reclamation systems, spent sands overheating degree and the efficiency of the system dedusting the reclaimed material operating in individual foundry plants.

In the article the results of investigations of physicochemical properties and thermal utilisation possibility referring to six kinds of after reclamation dusts generated in the mechanical reclamation process of spent moulding sands with furfuryl resins and six other kinds of after reclamation dusts obtained from reclamation process of spent moulding sands with alkaline resins have been presented. All tested dusts originated from various Polish foundry plants of cast iron and cast steel applying the mechanical reclamation process of moulding sands with resins, obtained from different producers.

Open access

J. Kowal, J. Dańko and J. Stojek

Abstract

The article presents examples of vibration signals analysis derived from the research of prototype reclaimer REGMAS. After the division of the time-frequency analysis methods of measuring signals, their non-parametric and parametric models were estimated. At the end of the article the summary and conclusions were set.

Open access

R. Dańko, J. Dańko and J. Stojek

Abstract

Experiments of filling the model moulds cavity of various inner shapes inserted in rectangular cavity of the casting die (dimensions: 280 mm (height) × 190 mm (width) × 10 mm (depth) by applying model liquids of various density and viscosity are presented in the paper. Influence of die venting as well as inlet system area and inlet velocity on the volumetric rate of filling of the model liquid - achieved by means of filming the process in the system of a cold-chamber casting die was tested. Experiments compared with the results of simulation performed by means of the calculation module Novacast (Novaflow&Solid) for the selected various casting conditions - are also presented in the paper.

Open access

J. Dańko, J. Kamińska and M. Skrzyńsk

Abstract

The results of the reclamation of spent moulding sands with inorganic binder in the prototype vibratory reclaimer REGMAS - are presented in the paper. Spent moulding sands with modified water-glass, burned as well as not burned, present in a form of agglomerates (lumps), were subjected to the reclamation processes.

During individual reclamation cycles the reclaimer efficiency and vibrations amplitudes were determined and physicalchemical and strength investigations were performed for the obtained reclaim materials. The obtained reclaim was used as a component of the matrix of moulding sands with water-glass in the Floster S technology, in which the reclaim constituted 100%, 80% and 50% of the sand matrix - respectively.

Open access

R. Dańko and J. Dańko

Abstract

The aim of the hereby paper is to present the developed model of determining the volume and surface porosity based on the main fraction of polifractional materials, its experimental verification and utilisation for the interpretation of effects accompanying the formation of a moulding sand apparent density, porosity and permeability in the blowing processes of the core and moulds technology.

Open access

R. Dańko, J. Dańko and M. Skrzyński

Abstract

The cumulative results of investigations of the possibility of using the reclaimed materials after the mechanical, thermal or mechanical-thermal reclamation for making cores by means of the blowing method in the alkaline CO2 technology, are presented in the paper. Three kinds of spent sands: with furfuryl resin, bentonite and alkaline phenolic resin, obtained from the foundry, were subjected to three kinds of reclamation: mechanical, thermal and combined mechanical-thermal, applying for this aim adequate experimental devices. The obtained reclaims were assessed with regard to the degree of the matrix liberation from the determined binding material. Reclaims of moulding sands with binders of the form of resin were assessed with regard to ignition loss values and pH reaction, while reclaims of moulding sands with bentonite with regard to the residual clay content and pH value. In all cases the results of the performed sieve analyses were estimated and the average characteristic diameter dl was determined. The reclaimed matrix was applied as a full substitute of the fresh high-silica sand in typical procedures of preparing core sands used for making shaped samples for bending strength investigations, Rg u.

Open access

J. Dańko, R. Dańko and M. Skrzyński

Abstract

The paper, especially dealt with problems of reclamation of used furan sand, carried out in new, vibratory sand reclamation unit REGMAS developed by researches from AGH-University of Science and Technology, Faculty of Foundry Engineering in Cracow (Poland). Functional characteristics of reclamation unit as well as the results of reclamation of used sand with furfuryl resin are discussed in the paper. The quality of reclaim was tested by means of the LOI and pH value, dust content in the reclaim and at least by the the quality of the castings produced in moulds prepared with the use of reclaimed matrix.

Open access

M. Skrzyński, R. Dańko and J. Kamińska

Abstract

The results of investigations of the reclamation of spent moulding and core sands, originated from one of the Polish foundry plants, are presented in the paper. Four mixtures consisting of two types of spent sands (spent moulding sand and spent core sand) were subjected to the regeneration process. Each tested mixture consisted of an inorganic type spent moulding sand and of an organic type spent core sand. Proportions of mutual fractions of spent moulding and core sands in mixtures was 70%-30% and was representative for the waste sands from the foundry, from which these sands originated.

Open access

J. Kamińska and J. Dańko

Abstract

The results of investigations of the granulation process of foundry dusts generated in the dry mechanical reclamation process of used sands, where furan resins were binders are presented in the paper. Investigations concerned producing of granules of the determined dimensions and strength parameters.

Granules were formed from the dusts mixture consisting in 50 mass% of dusts obtained after the reclamation of the furane sands and in 50 mass % of dusts from sands with bentonite. Dusts from the bentonite sands with water were used as a binder allowing the granulation of after reclamation dusts from the furane sands.

The following parameters of the ready final product were determined: moisture content (W), shatter test of granules (Wz) performed directly after the granulation process and after 1, 3, 5, 10 days and nights of seasoning, water-resistance of granules after 24 hours of being immersed in water, surface porosity ep and volumetric porosity ev. In addition the shatter test and water-resistance of granulate dried at a temperature of 105°C were determined.

Investigations were performed at the bowl angle of inclination 45°, for three rotational speeds of the bowl being: 10, 15, 20 rpm.

For the speed of 10 rpm the granulation tests of dusts mixture after the preliminary mixing in the roller mixer and with the addition of water-glass in the amount of 2% in relation to the amount of dust were carried out.

The obtained results indicate that the granulator allows to obtain granules from dusts originated from the reclamations of moulding sands with the furane resin with an addition of dusts from the bentonite sands processing plants.

Open access

J. Kamińska and J. Dańko

Abstract

A technology of sands with water glass hardened by liquid esters is a cheap and ecologic method of producing moulding sands. Due to these advantages, this technology is still very important in several foundry plants for production of heavy iron and steel castings. Reclamation of the mixed moulding and core sands generates significant amounts of dusts, which require further treatments for their reuse. The results of investigations of a pressureless granulation of dusts generated in the dry mechanical reclamation process of the mixture consisting in app. 90 % of moulding sands from the Floster S technology and in 10 % of core sands with phenolic resin resol type, are presented in the hereby paper. Investigations were aimed at obtaining granulates of the determined dimensional and strength parameters.

Granules were formed from the mixture of dusts consisting of 75 mass% of dusts after the reclamation of sands mixture and of 25 mass% of dusts from bentonite sands processing plant. Wetted dusts from bentonite sands were used as a binding agent allowing the granulation of after reclamation dusts originated from the mixed sands technology.