Technological equipment of materials production -

Ministry of Education and Science of the Republic of Kazakhstan

Karaganda State Technical University

Approved by

the Chairman of the Academic Council, Rector, Academician of NAS of the RK GazaliyevA.M.

_______________________

“____” _________ 2013

Syllabus

Course TEMP 3305 « Technological equipment of materials production »

Module TPMP 32 « Technological processes of materials production »

Major 5В071000 – «Materials Science and Technology of New Materials”

Mechanical Engineering Institute

Department of Metallurgy, Materials Science and Nanotechnologies

2013

Preface

Working educational program is worked out by Associate professor Kulikov V.Yu, senior tutor Yudakova V.A.

Discussed at the meeting of the department « Metallurgy, Materials Science and Nanotechnologies »

Minutes № _______ of ______________ «____» _____________20___

Head of department __________ KulikovV.Yu. «____» _________20___

(signature)

Approved by the Educational Consul of the Institute of Mechanical Engineering

Minutes № _______ of ______________ «____» 20___

Chairman________________ Sherov K.T. «____» __________20___

(signature)

Tutor’s personal data and contact information

Associate professor Kulikov V.Yu.

Senior tutor Yudakova V.A.

«Technology of Mechanical Engineering» department in the main building of KSTU, B. Mira, 56 room No.313, contact phone 56-59-35 add. 1024.

Course labour intensity

Term	credits / ЕCTS	The type of classes					Type of classes	number of AL	Total number of hours
		number of contact hours			number of OH	Total hours
		lectures	practical classes	laboratory classes
7	3/5	30	–	15	45	90	45	135	Examination

Course description

Course «Technological equipment of materials production ” part of a series of specialized disciplines. Process equipment manufacture of materials is a complex discipline that contains basic information about equipment used in the manufacture of materials and articles made of metallic and non-metallic materials.

Course purpose

Course «Technological equipment of materials production ” aims to familiarize students with the basic types of process and auxiliary equipment used in the production of materials; principles for their design, calculation and use.

Course objectives

Course objectives are: the study of basic technological design to gain experience of design and calculation of various equipment , reporting, writing essays and articles.

As a result of studying this discipline students must :

student knows:

– The principles of operation of the equipment used in the production of materials ;

– structure of the machine-building plants ;

– relationship of equipment in a single process ;

– the principles of operation of the equipment ;

– method of calculating the parameters of the design and development of components and mechanisms ;

– laws of nature and the mutual influence of aerodynamic , chemical, heat transfer processes ;

student is able:

– to work with spetsliteraturoy and directories ;

– analyze the factors that determine the operating characteristics of the equipment ;

– to operate the equipment used ;

– to carry out design calculations and drawings pieces of equipment ;

acquire practical skills:

– calculating the heat transfer by radiation and convection in the fuel and an electric furnace ;

– calculation of the heat of the furnace .

Prerequisites

Studying of this Course requires assimilation of the following Courses (with the indication of sections (subjects)):

Course	Name of sections (subjects)
1 Higher Mathematics	Differential calculus
2 Chemistry	Mendeleev’s periodic system. The chemical properties of metals. Oxidation-reduction reactions.
3 Physics	The structure and physical properties of metals. Mechanics. Electromagnetism.
3 Descriptive Geometry and Engineering Graphics	Cuts, sections, perspective geometry.
4 Machine Parts	full course
5 Electrical	full course

Post requisites

The knowledge received at studying of course ” Technological equipment of materials production “, is used at implementation of special sections of the degree project (work).

Thematic plan of course

Name of section (subject)	Labour intensity on types of classes
Name of section (subject)	lectures	practical	laboratory	OH	AL
1	2	3	4	5	6
1.Introduction. Fundamentals of Thermodynamics	2	3	–	3	3
2. Equipment for the production of pig iron	2	3	–	3	3
3. Equipment for the production of steel	2	3	–	3	3
4. Equipment for the production of aluminum	2	–	–	3	3
5. Equipment for the production of magnesium	2	–	–	3	3
6. Equipment for the production of titanium	2	–	–	3	3
7. Equipment for the production of copper	2	–	–	3	3
8. Equipment for the production of foundry	2	–	–	3	3
9. Manufacturing equipment and pressure	2	6	–	3	3
10. Equipment for the production of rolling	2	–	–	2	2
11. Other machinery for making drawing	2	–	–	2	2
12. Equipment for producing compression	1	–	–	2	2
13. Equipment for the manufacture of free forging	1	–	–	2	2
14. Equipment for the production of forging	1	–	–	2	2
15. Equipment for the production of sheet metal forming	1	–	–	2	2
16. Equipment for the production of welding products	2	–	–	3	3
17. Equipment for the production of non-metallic materials	2	–	–	3	3
TOTAL:	30	15		45	45

List of laboratory classes

1. Calculation of heat radiation of the fuel and an electric furnace.

2. Calculation of heat transfer by convection.

3. The calculation of the thermal performance of the furnace.

4. Study design and operating processes in a blast furnace.

5. The study of the design and operating processes in the open-hearth furnace.

Criteria of students’ knowledge assessment

The examination mark is determined by course as the sum of the maximum indexes of progress on midterm controls (to 60%) and to final attestation (examination) (to 40%) and makes value to 100% according to the table.

Grade on alphabetic system

Numerical

equivalents

Percentage

Traditional

system

А-

4,0

3,67

95-100

90-94

Excellent

В+

В-

3,33

3,0

2,67

85-89

80-84

75-79

Good

С+

С-

D+

D-

2,33

2,0

1,67

1,33

1,0

70-74

65-69

60-64

55-59

50-54

Satisfactory

0-49

Unsatisfactory

Grade «A» (excellent) is put in the case if student during a term showed perfect knowledge of all program questions of course, and also of subjects of independent work, regularly handed over midterm tasks, showed independence in studying of theoretical and applied questions according to the main program of studied course, and also on extra program questions.

Grade «A-» (excellent) stipulates perfect knowledge of basic laws and processes, concepts, ability to generalization of theoretical questions of course, regular handing of midterm tasks of classroom and independent work.

Grade “B+” (good) is put in the case if student showed good and excellent knowledge of course questions, regularly handed over term tasks generally on “excellent” and some on “good”.

Grade “B” (good) is put in the case if student showed good knowledge of the questions opening the main maintenance of a concrete subject of course, and also subject of independent work, regularly handed over term tasks on “good” and “excellent”.

Grade “B-” (good) is put to a student in the case if he well is guided in theoretical and applied questions of course both on classroom, and on AL subjects, but irregularly handed over midterm tasks and had cases of a repeating an examination of term tasks on course.

Grade “C+” (satisfactory) is put to a student in the case he owns questions of conceptual character by all types of room classes and AL, can open the maintenance of separate modules of course, hands over on “good” and “satisfactory” term tasks.

Grade “C” (satisfactory) is put to a student in the case he owns questions of conceptual character by all types of room classes and AL, can open the maintenance of separate modules of course, hands over on “satisfactory” term tasks.

Grade “C-” (satisfactory) is put to a student in the case student during a term regularly handed over term tasks, but concerning room classes and AL owns only the general concepts and can explain only separate regularities and their understanding within a concrete subject.

Grade “D+” (satisfactory) is put to a student in the case he irregularly handed over term tasks concerning room classes and AL owns only the general concepts and can explain only separate regularities and their understanding within a concrete subject.

Grade “D-” (satisfactory) is put to a student in the case he irregularly handed over term tasks, concerning room classes and AL, owns the minimum volume of knowledge, and also allowed admissions of classes.

Grade “F” (unsatisfactorily) is put when student practically doesn’t own the minimum theoretical and practical material of room classes and AL on course, irregularly visits classes and doesn’t hand over in time term tasks.

Midterm control is carried out on the 7, 14 weeks of study and it develops proceeding from the following types of control:

Type of control

Percentage

Academic period of study, week

Total, %

Attendance

0,7

10,0

Lectures notes

3,0

6,0

Test quiz

5,0

10,0

1,0

14,0

Handing of course project

20,0

Examination

Total on attestation

Total

100

Policies and procedures

When studying course «Technological equipment of materials production »

I ask to observe the following rules:

1. Not to be late for classes.

2. Not to skip classes without a good reason, in case of an illness I ask to provide the reference, in other cases – an explanatory note.

3. Duties of the student include visit of all types of occupations.

4. According to the schedule diagram of educational process to hand over all types of control.

5 Passed laboratory researches to fulfill during time specified by the teacher.

Educational and methodical provision of course

Author	Literature		Publishing house, year of the issue		Number of copies
					in library			in library
Main literature
Арутюнов В.А.		Metallurgical and other heating equipment	2004		3			–
Свечанский А.Д.		Electric industrial furnaces	2005		3			–
Аксенов П.И.		Foundry	2007.		–			–
Дальский А.М.		Technology of construction materials	2009, 2002. .		–			–
Additional literature
Дриц М.Е., Москалев М.А.	Technology of construction materials and materials science			, 2009		*	–
Титов Н.Д.	The technology foundry			2005.		*	–

Schedule of performing and passing tasks on course

Type of control	Purpose and content of assignment	Recommended literature	Duration	Form of control	Handing term
Performing practical of the number 1	Calculation of Funds time	[1], [2], [3]	3 weeks	current	3 weeks
Performing practical of the number 2	The calculation of the performance and the amount of equipment	[1], [2], [3]	3 weeks	current	6 weeks
abstract	The calculation of the production program	[1], [2], [3]	6 weeks	current	6 weeks
Written survey number 1	Types of buildings, building elements	[1], [2], [3], [5],	1 contacthour	Midterm	7 weeks
Report on the AL (theme 1)	The layout of plants and layout	[1], [2], [3], [4], [5], [6]	7 weeks	Midterm	7 weeks
Performing practical of the number 3	Disposition of plant, equipment placement	[1], [2], [3]	3 weeks	current	9 weeks
Performing practical of the number 4	Calculation of maintenance for equipment	[3], [4], [5], [6]	3 weeks	current	12weeks
Performing practical of the number 5		[3], [4], [5], [6]	3 weeks	current	14weeks
Report on the AL (theme 2)		[1], [2], [3], [4], [5], [6], [7]	7 weeks	Midterm	14weeks
Written survey number 2		[1], [2], [3], [4], [5], [6],	1 contacthour	Midterm	14weeks
Examination	Checking learning styles discipline	All list of the main and additional literature	2 contact hours	Final	During examinationperiod

Questions for self-checking

1. Types and designs of pressing devices.

2 . Workflow pressing mechanism with hydraulic drive.

3 . Determination of the main parameters of extrusion machinery.

4 . Analysis of the structure and workflow GSP machine.

5 . The design and operation of shaking mechanisms.

6. Design and operation and core-shooting heads.

7. Scope, design and operation of pulsed heads.

8. Special machines for making molds and cores .

9. Block diagrams , structure and operation of the PR of different generations.

10 . Scope, block diagrams , component parts , advantages and disadvantages of drives PR.

11. The construction and operation of robotic.

12. RTC processing operations and special types of molding.

13. The layout of the elements ( main, auxiliary and transport ) and the work of APL .

14. Design and operation flask and APL .

15. System kit and loading into the melting furnace charge .

16. System of preparation and distribution of molding and core sand .

17. Regeneration systems waste mixture.

18. Design and operation of core flow-line and automated lines .

19. Design and operation of the lines of chemical and electrochemical treatment .

20. Design and operation of flow-line and automated lines stumps and cleaning castings.

19. The principle of operation of pulse machines.

20. Pulsed low-pressure machines .

21. Pulse compression mechanism .

22. Design and operation of RTK data link .

23. Shooting machine for rod heated by a snap.

24. Shooting machine for shell cores .

25. Preparation rods in cold box by a machine.

26. SUMMARY high compression.

27. The principle of action of the GSP.

28. Combination and special forming machines .

29. Work and construction of specialized core machines.

30 . The principle of operation and the device.

31. Molding production lines .

32. Tilters assignment , device.

33. Types of casting ladles.

34. . What purpose of attestation?

35. Design and operation of MHD casting devices.

36. The construction and operation of manipulators mold-release agent .

37. Production lines for the manufacture of self-hardening stezhney rods.

38. The principle of construction of the indicator diagram of reciprocating forming machine .

39. Design and operation of explosive molding machine .

40 . Analysis of the distribution density of the sand height forms with different methods of molding machine .

41. Design and operation of the lines of chemical and electrochemical treatment .

42. Design and operation of flow-line and automated lines stumps and cleaning castings.

43. For what purpose and in what ways are subjected to blister copper refining ?

44. What is the essence of the foundry, and what is its significance?

45 . How does the cupola ?

46. What are the signs and are classified as rolling mills ?

47. What applies to the production of rolling mills ?

48. What is a drawing which hardware it is running ?

49. What equipment is pressing, and how it is implemented ?

50 . What equipment is forging ?

51. What is called the stamping ? What kinds of it is divided ?

52. What are the advantages of forging ?

53. What are the current sources are used in arc welding ?

54. What distinguishes the work of the hammer from the press?

55. What equipment is used in welding ?

State pub. lic. No. 50 of 31.03.2004 Passed for printing

Format 60х90/16

Printers sheets sh. Number of copies cop. Order Contract price

__________________________________________________________________

Publishing house of Karaganda State Technical University