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Iron-Foundry Production
Iron-foundry production of MTW has two foundry shops for manufacture of gray cast-iron castings: production shop of large body castings from 35 kg to 250 kg, and production shop of small and medium size castings from 0.5 kg to 55 kg. Form making in iron-foundry shops is carried out on automatic transfer lines of Gizag Company with molding-box clear dimensions of 1000õ800õ300/300 mm, Disamatic 2013MK-5A, home-made automatic transfer press lines with casting-box dimensions of 900õ600õ300/300 mm.
For cast iron melting there are cupolas in the shops with 20 t/h output, watering cooling system, gas reburning system and spark suppression. Heating and refining of cast iron are made in Piks-20/800 induction hot-air furnaces and in Jynker RGD-GE 3/250 furnace with induction heating.
Making of sand blend is done in AMK-2000H and Speedmuller 85Â mixers. Making of cores is carried out by automatons with curing in hot boxes.
Cleaning of castings is carried out in shot-blast cleaning chambers and drums of periodical and continuous action. Castings are finished by grinding machines and automatic transfer lines.
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Steel-Foundry Production
Steel-foundry production of works was created in steel-foundry shop with production of carbon cast shapes from 2.5 to 70 kg.
Form making in shop is carried out from sand-clay mixtures in moulding boxes of 90õ60õ250/250 mm and 960õ770õ300/300 mm sizes. For steel melting there are arc electric ovens of 5t capacity in the shop.
For form making of form mixture shop is equipped with AMK-2000H mixers.
Making of cores is carried out in automatons with curing in hot boxes.
Cleaning of castings is carried out in cleaning shot-blasting chambers and crusher drums of periodical and continuous action.
Castings are finished on grinding machines and automatic transfer lines.
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Casting in Meltable Models
Casting in meltable models. Production of castings with complex configuration from 10 g to 1 kg with wall thickness of 1.5-2 mm and small extent was created in precision steel casting shop using the method of casting in meltable models.
High productivity automatic machines have been installed in the shop to produce precision steel castings.
Castings are produced by casting liquid metal into ceramic forms obtained by applying four-layer ethyl silicate coat on model block.
Precleaning of filled blocks from ceramics and separation of castings are carried out by semiautomatons.
Final cleaning of castings from residual ceramics is done by chemical treatment of castings (leaching in drums).
At a final stage of production, castings are subjected to normalization in furnaces with protective atmosphere, separation by name rejecting defect castings, residue fetting of feeders by grinding machines or cutting on presses, casting dressing, remedy of faults, and final casting inspection.
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Forging and Thermal Production
Forgings of 0.1-50 kg are produced in blacksmith's shop. Average mass of forging is 3,5 kg. Heating of blanks before stamping is carried out in gas heating furnaces and in induction blacksmith heaters.
The following processes are widely used: forge-rolling before stamping, cold embossing of forgings instead of mechanical machining, hot pressing-out of forgings, rolling of forgings on the VWQ 40õ400 mill, collecting of metal before stamping on an electric upsetting heading machine and other processes of hot casting production.
Thermal production has the necessary base for thermal treatment of all Belarus tractor parts with the capacity of output of 100 thousand tractors a year.
The following types of thermal treatment were put into operation at MTW:
- water broken-hardening of blanks, forgings of chrome and chrome-nickel steel;
- isothermal annealing of blanks, forgings of alloy steel;
- light hardening of parts in PEKAT furnaces of ALTHERMA Company;
- chemical-thermal treatment of parts with automatic control and testing of furnace atmosphere;
- cyoniding of parts in salt bathes;
- borating of parts and tools in powder and coatings;
- electrolyzed borating of parts in salt bathes;
- nitriding, carbonitriding of pieces in shaft furnaces;
- rf current thermal treatment.
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