Numerical Simulation and Optimization of Furnace Roll Casting Production Technology

Kód výsledku v IS VaVaI

<a href="https://www.isvavai.cz/riv?ss=detail&h=RIV%2F61989100%3A27360%2F25%3A10258960" target="_blank" >RIV/61989100:27360/25:10258960 - isvavai.cz</a>

Výsledek na webu

<a href="https://www.mdpi.com/1996-1944/18/23/5445" target="_blank" >https://www.mdpi.com/1996-1944/18/23/5445</a>

DOI - Digital Object Identifier

<a href="http://dx.doi.org/10.3390/ma18235445" target="_blank" >10.3390/ma18235445</a>

Jazyk výsledku

angličtina

Název v původním jazyce

Numerical Simulation and Optimization of Furnace Roll Casting Production Technology

Popis výsledku v původním jazyce

This study investigates the use of steel and cast iron for producing cast furnace rolls to replace welded rolls, which often fail from cracks and limited durability. Casting had not been previously considered by the manufacturer, but rising demands for durability and quality make it a promising alternative. Material selection focused on mechanical properties, wear resistance, and production costs. To ensure casting quality, Magmasoft 6.0 software was applied for detailed simulation of casting, solidification, and cooling. Results showed that steel alloys (GS-34CrMo4 and GS-20Mn5) are prone to shrinkage and porosity, which cannot be fully avoided even with feeders. In contrast, GJS-500-7 cast iron exhibited low shrinkage tendency and minimal defects, proving suitable for production while reducing costs. It also offers lower weight and efficient metal use, improving cost-effectiveness. Detected defects were concentrated in the central casting area, where they have little impact on functionality. Based on sixteen simulations, GJS-500-7 cast iron emerged as the most suitable material for furnace rolls thanks to its thermal resistance, castability, low porosity, and ability to meet required specifications. This process optimization represents an efficient, cost-effective choice, improving final product quality and creating new opportunities for the manufacturer.

Název v anglickém jazyce

Numerical Simulation and Optimization of Furnace Roll Casting Production Technology

Popis výsledku anglicky

This study investigates the use of steel and cast iron for producing cast furnace rolls to replace welded rolls, which often fail from cracks and limited durability. Casting had not been previously considered by the manufacturer, but rising demands for durability and quality make it a promising alternative. Material selection focused on mechanical properties, wear resistance, and production costs. To ensure casting quality, Magmasoft 6.0 software was applied for detailed simulation of casting, solidification, and cooling. Results showed that steel alloys (GS-34CrMo4 and GS-20Mn5) are prone to shrinkage and porosity, which cannot be fully avoided even with feeders. In contrast, GJS-500-7 cast iron exhibited low shrinkage tendency and minimal defects, proving suitable for production while reducing costs. It also offers lower weight and efficient metal use, improving cost-effectiveness. Detected defects were concentrated in the central casting area, where they have little impact on functionality. Based on sixteen simulations, GJS-500-7 cast iron emerged as the most suitable material for furnace rolls thanks to its thermal resistance, castability, low porosity, and ability to meet required specifications. This process optimization represents an efficient, cost-effective choice, improving final product quality and creating new opportunities for the manufacturer.

Druh

J_imp - Článek v periodiku v databázi Web of Science

CEP obor

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OECD FORD obor

20500 - Materials engineering

Projekt

Výsledek vznikl pri realizaci vícero projektů. Více informací v záložce Projekty.

Návaznosti

P - Projekt vyzkumu a vyvoje financovany z verejnych zdroju (s odkazem do CEP)

Rok uplatnění

2025

Kód důvěrnosti údajů

S - Úplné a pravdivé údaje o projektu nepodléhají ochraně podle zvláštních právních předpisů

Název periodika

Materials

ISSN

1996-1944

e-ISSN

1996-1944

Svazek periodika

18

Číslo periodika v rámci svazku

23

Stát vydavatele periodika

CH - Švýcarská konfederace

Počet stran výsledku

28

Strana od-do

nestránkováno

Kód UT WoS článku

001635066300001

EID výsledku v databázi Scopus

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