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Ministry of Education and Science of the Republic of KazakhstanNon-commercial Joint stock Company «Holding «Kasipkor»

EDUCATIONAL PROGRAMon the specialty: 1004000 – Foundry

Qualifications:

– 100402 2 – Mechanic-foundryman on machines and automatic lines*

– 100406 2 – Core maker of machine molding *– 100407 2 – Core maker of hand molding *– 100409 3 – Technician-metallurgist – ******** – Assistant Foundry Production Engineer

PART 1

Astana – 2015

CONTENTIntroduction 3Curriculum 4Explanatory note to structure and content 10Structure and content of educational program 63Educational programs on the disciplines 82

Basics of engineering graphics 82Basics of technical mechanics 95Electro technics with the basics of electronics 116Basics of standardization and metrology 136Metal technology and welding 155Heat engineering 177Records management in state language 189

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INTRODUCTION

This educational program is based on the competence approach, taking into account modern international requirements for mid-level specialists and skilled workers, with the participation of foreign partner EI «RIPE» (Republic of Belarus).

The educational program is based on competencies, designed with the concept of lifelong learning, as the content of educational programs aimed at the formation of highly qualified specialists, capable of adapting to changing situations at work, on the one hand, and to continue professional development and education, on the other.

This approach to training allows to create a feeling of success of each student, which is created by the organization of educational process in which the learner can and should take over control of own learning, which teaches him to take responsibility for own learning, and in the future – for own professional growth and career . Thus, student as a consumer will be satisfied with education; he/she can improve it for life, responding to changes in labor market.

The educational program on the specialty contains information on the relevant levels of qualification, professional profile, curriculum, the requirements for applicants and the implementation of vocational training. This takes into account the requirements for competences of qualification levels 3, 4 and 5 of the National Qualifications Framework of the Republic of Kazakhstan.

The educational program on a specialty «Foundry» designed to meet basic provisions of:

Law of the Republic of Kazakhstan «About Education» dated July 27, 2007; State Program for Education Development of the Republic of Kazakhstan

for 2011-2011 years (Presidential Decree dated December 7, 2010 №1118); Development Strategy of NC JSC «Holding «Kasipkor» for 2012-2021 years

(DGRK dated December 31, 2011 №1751); State program on industrial-innovative development of the Republic of

Kazakhstan for 2015-2019 years (Presidential Decree dated March 19, 2010 № 957);

National Qualifications Framework of the Republic of Kazakhstan (joint order of Minister of Labour and Social Protection of the Republic of Kazakhstan dated 24 September 2012 №373, and Minister of Education and Science of the Republic of Kazakhstan dated 28 September 2012 №444).

It provides an opportunity to assign such qualifications as «1004022 Mechanic-foundryman on machines and automatic lines*», «1004062 Core maker of machine molding*», «1004072 Core maker of hand molding*», «1004093 Technician-metallurgist» and «******* Assistant Foundry Production Engineer».

To implement this program in the practice of the institution, institution needs to develop working curricula and programs depending on the features of labor market in region and requirements of customer-employer.

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CURRICULUM

Specialty: 1004000 – FoundryQualifications: 100402 2 – Mechanic-foundryman on machines and automatic lines *

100406 2 – Core maker of machine molding *100407 2 – Core maker of hand molding *100409 3 – Technician-metallurgist ******* – Assistant Foundry Production Engineer

Study form: full-timeDuration of study: 3 years 6 months

on the basis of: general secondary education

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1 2 3 4 5 6 7 8 9 10 11 12Qualification 100407 2 – Core maker of hand molding *

1 All humanities disciplines (Professional Kazakh (Russian) language, professional foreign

236 1-2

1 2 3 4 5 6 7 8 9 10 11 12language, history of Kazakhstan, physical culture)

2 General professional disciplines 304 148 156 1-22.1 Basics of engineering graphics + + 46 16 302.2 Basics of technical mechanics + + + 102 60 422.3 Electro technics with the basics of electronics + + 40 16 242.4 Basics of standardization and metrology + + 30 20 102.5 Metal technology and welding + + 38 20 182.6 Heat engineering + + 48 16 323 Special disciplines 210 136 74 1-2

3.1 Theory and technology of foundry + + 96 64 323.2 Foundry alloys and melting + + 40 26 14

3.3 Design and technological basis for the production of moulds for manual molding + + 22 12 10

3.4 Economics, organisation and planning of production + + 28 20 8

3.5 Safety and health management + + 24 14 104 Disciplines, defined by the educational

organisation **24 –

152** 1-2

5 Industrial training and professional practice 5765.1 Industrial training 288

5.1.1 Fitting and mechanical training practice 288 15.2 Professional practice 288

5.2.1 Industrial training on the acquisition of worker profession “Core maker of hand molding” 288 2

6 Midterm examination 54 1-27 Final examination 36 2

7.1 Final examination *** 24

7.2The assessment of professional qualification level and the awarding of qualification “ Core maker of hand molding ”

12

8 Total for compulsory education for 10 months 1440

5

1 2 3 4 5 6 7 8 9 10 11 12Qualifications:100402 2 – Mechanic-foundryman on machines and automatic lines *

100406 2 – Core maker of machine molding *9 All humanities disciplines (physical culture) 44 310 General professional disciplines 172 112 60 3

10.1 Basics of engineering graphics + + 54 36 1810.2 Electro technics with the basics of electronics + + 32 22 1010.3 Basics of standardization and metrology + + 38 18 2010.4 Metal technology and welding + + 48 36 1211 Special disciplines 162 102 60 3

11.1 Foundry alloys and melting + + 68 48 2011.2 Automation of foundry + + 72 42 30

11.3 Design and technological basis for the production of moulds for machine molding + + 22 12 10

12 Disciplines, defined by the educational organisation **

18 – 102** 3

13 Industrial training and professional practice 39613.1 Professional practice 396

13.1.1 Industrial training on the acquisition of worker profession “Core maker of machine molding” 180 3

13.1.2Industrial training on the acquisition of worker profession “ Mechanic-foundryman on machines and automatic lines ”

216 3

14 Final examination 72 314.1 Final examination *** 60

14.2

The assessment of professional qualification level and the awarding of qualification “ Core maker of machine molding ” and “Mechanic-foundryman on machines and automatic lines“

12

15 Total for compulsory education for 1 year 6 months 2304

6

1 2 3 4 5 6 7 8 9 10 11 12Qualification 100409 3 – Technician-metallurgist

16All humanities disciplines (Professional Kazakh (Russian) language, professional foreign language, history of Kazakhstan, physical culture)

204 4-5

17Socio-economic disciplines (cultural studies, the basics of philosophy, economy, political science and sociology, law basics)

180 4-5

18 General professional disciplines 152 72 80 418.1 Records management in state language + 76 36 4018.2 Basics of computer technology in the industry + + 76 36 4019 Special disciplines 368 168 92 108 4-5

19.1 Theory and technology of foundry + + 40 8 2 30

19.2 The systems of computer-aided design and simulation of foundry processes + + 56 22 34

19.3 Design of rigging + + + + 102 44 34 2419.4 Automation of foundry + + + 70 32 8 30

19.5 Economics, organisation and planning of production + + + 52 26 2 24

19.6 Safety and health management + + 48 36 1220 Disciplines, defined by the educational

organisation **50 –

180** 4-5

21 Industrial training and professional practice 93621.1 Professional practice 936

21.1.1 Industrial training on design and production of machining attachments 180 5

21.1.2 Technological practice 540 621.1.3 Engineering project 216 6

22 Midterm examination 90 4-523 Final examination 36 6


7

1 2 3 4 5 6 7 8 9 10 11 12

23.2The assessment of professional qualification level and the awarding of qualification “Technician-metallurgist ”

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24 Total for compulsory education for 2 years 10 months 4320

Qualification******* – Assistant Foundry Production Engineer25 All humanities disciplines (physical culture) 28 7

26 Basic disciplines(Chemistry) 135 7

27 Special disciplines 161 95 66 727.1 Automatic lines and systems + + 75 43 3227.2 Automation of foundry production + + 86 52 34

28 Disciplines, defined by the educational organisation **

18 – 58** 7

29 Professional practice 43229.1 Pre-diploma practice 216 729.2 Diploma projection 216 730 Midterm examination 54 731 Final examination 36 7


31.2The assessment of professional qualification level and the awarding of qualification “Assistant Foundry Production Engineer ”

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32 Total for compulsory education for 3 years 6 months 5184

33 Consultations Not more than 100 hours per academic year34 Facultative studies Not more than 4 hours per week during the period of theoretical training35 Total 5800

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Notes:* According to State educational standards of TVET the list of disciplines is compulsory for implementing in a standard

curriculum. The forms of control (number of term papers, tests, exams), the order of the studying the subjects (distribution according to courses) are approximate and may vary depending on the mode of study, the specifics of specialties, local and other conditions (circumstances), including the needs of employer.

** The amount of hours per disciplines is defined by educational organisation, and can be increased by reducing the amount of hours (up to 25%) of cycles of general and special disciplines.

*** Recommended forms of final certification: for qualification 100407 2 - Core maker of hand molding *- passing the comprehensive examination on special disciplines (3.2, 3.3, 3.5), for qualification 100406 2 – Core maker of machine molding * - passing the comprehensive examination on special disciplines (3.2, 3.5, 11.3); for qualification 100402 2 – Mechanic-foundryman on machines and automatic lines - passing the comprehensive examination on special disciplines (3.2, 3.5, 11.2); for qualification 100409 3 - Technician-metallurgist - passing the comprehensive examination on special disciplines (11.1, 19.1, 19.), for qualification ******* Assistant Foundry Production Engineer - the protection of diploma project.

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EXPLANATORY NOTE to structure and content of educational program

by specialty 1004000 «Foundry»

Duration of training of the educational programme of TVET at full-time training on the basis of general secondary education is 3 years and 6 months.

The content of the technical and vocational education training programme includes the study of such disciplines as the humanities and social sciences along with the vocational disciplines, humanities and social sciences are in this case integrated with occupational training programmes of the 1st and 2nd year of higher education. Upon completion of the training the qualification “Assistant foundry production engineer” is awarded.

The standard curriculum is designed in form of blocks of disciplines, which allows to relate their study to getting the qualification of a worker, technician or junior engineer. After the first year students have the opportunity to enter the labour market with the qualification “Core maker of hand molding” of the 2nd level of the NQF. The recommended form of the final certification is comprehensive examination in special disciplines (see the standard curriculum, special disciplines 3.2, 3.3, 3.5).

After 1 years and 6 months, the students of the 2nd year will have the opportunity to enter the labour market or, according to the opinion of the TVET institution, or in the opinion of personnel customer’s requirements, - based on the results of study during 1 year and 10 months, with the qualifications “Core maker of hand molding” of the 2nd NQF level, “Core maker of machine molding” of the 2nd NQF level and “Mechanic-foundryman on machines and automatic lines” of the 3rd NQF level. The recommended forms of the final certification are: for the qualification 100406 2 – Core maker of machine molding* – comprehensive examination in special disciplines (see the standard curriculum, special disciplines 3.2, 3.5, 11.3), for the qualification 100402 2 – Mechanic- foundryman on machines and automatic lines* – comprehensive examination in special disciplines (see the standard curriculum, special disciplines 3.2, 3.5, 11.2).

Hereafter students will have the opportunity to enter the labour market in 2 years and 10 months with the qualifications “Core maker of hand molding” of the 2nd NQF level, “Core maker of machine molding” of the 2nd NQF level, “Mechanic- foundryman on machines and automatic lines” of the 3rd NQF level, and “Technician-metallurgist” of the 4th NQF level. The recommended form of the final certification for the qualification 100409 3 – Technician-metallurgist – is comprehensive examination in special disciplines (see the standard curriculum, special disciplines 11.1, 19.1, 19.3).

At the beginning of the 3rd year students, who have a wish to get an education as applied undergraduate, with the average level of performance no less than four points, write an application addressed to the head of the educational institution. Based on the applications processed a list of students is determined, who will study during the period of 3 years and 6 months in total.

During the 4th year, upon completion of the study, the students receive a diploma of education with the qualification of “Assistant foundry production engineer” of the 5th level of the NQF. The recommended form of the final certification for the qualification ******* – Assistant foundry production engineer – is the defense of a diploma project.

The organisation of industrial training and professional practice includes:- training and industrial work on the acquisition of professional skills

(industrial training); - training and industrial work on the acquisition and development of

professional skills (professional practice of “Industrial training on the acquisition of worker profession”, training at production);

- professional practice (technological, pre-diploma).The duration of each type of practice is determined in accordance with the

requirements of the qualification profile of specialists with the qualifications “Technician- metallurgist” and “Assistant foundry production engineer”.

Industrial training is carried out in training and production workshops under the guidance of a master of industrial training.

Terms and content of professional practice are defined by working curricula and working training programmes.

It is provided for learners to master a number of related worker qualifications with the assignment of grade during the period of practice: “Core maker of hand molding”, “Core maker of machine molding”, “Mechanic- foundryman on machines and automatic lines”.

Professional practice is carried out in relevant organisations at workplaces provided by employers on the basis of contract and is aimed at consolidating knowledge acquired during the training, at acquisition of practical skills and professional competences.

Distance learning technologies (hereinafter – DLT) can be used with introduction of educational training programme in educational activities of TVET institutions.

The implementation of DLT is performed on the following types: TV technology, network technology and case technology.

DLT is applied to students:- by shortened educational programmes on the basis of technical and

vocational, post-secondary and higher education; - for persons with disabilities, including disabled children, disabled of

groups I and II.Organisations must have electronic training and methodological complexes

in all disciplines of the curriculum implemented by using DLT. Preparation of electronic training and methodological complexes/teaching aids is provided by the developer of the course according to approved working training programmes, developed in accordance with the standard training programme.

Technical and vocational educational establishments have an opportunity to provide module education by this curriculum.

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Taking into account that a module program is a part of curriculum aimed at acquiring knowledge, skills and competences necessary to perform certain kinds of vocational activities within one field, the contents of each program module is provided as a completed education stage with competences, learning outcomes and assessment criteria specified.

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MODULAR PROGRAMS CONTENT DESCRIPTION

Specialty: 1004000 – FoundryQualifications: 100402 2 – Mechanic-foundryman on machines and automatic lines *

100406 2 – Core maker of machine molding *100407 2 – Core maker of hand molding *100409 3 – Technician-metallurgist ******** – Assistant Foundry Production Engineer

Basic competences (BC)BC 1 Work with technical documentsBC 2 Search for scientific and technical information and arrange it in a systemBC 3 Work for high quality resultBC 4 Plan working timeBC 5 Plan individual working activitiesBC 6 Work individually and in a teamBC 7 Comply with the rules of interpersonal and communicative conductBC 8 Arrange working placeBC 9 Acknowledge the importance of complying with the requirements of labor protection and occupational safety.BC 10 Update knowledge and skills throughout the rest of lifeBC 11 Work with legal literature and labor legislationBC 12 Arrange the work of contractor team to reach the goals setBC 13 Interact with experts in related fields.BC 14 Analyze and assess the data collected

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Professional competences (PC)1. Qualification 100407 2 Core maker of hand molding *of NRK (National qualifications Framework) 2nd

level

PC 1. Control the quality of core sands and the condition of core boxesPC 1.2 Make cores by core boxes with detachable parts, frames and cagesPC 1.3 Make cores from ceramic mixture for casting from special alloysPC 1.4 Make cores from free-running, self-hardening and cold-hardening sandsPC 1.5 Perform cleaning, gluing and assembling of coresPC 1.6 Perform core finishingPC 1.7 Perform filling, ramming, deleting of separate parts, cleansing and painting for complex coresPC 1.8 Make complex middle-sized cores of medium-complex large-sized cores by a template

2. Qualification 100406 2 – Core maker of machine molding * of NRK 2nd level

PC 2.1 Prepare core boxesPC 2.2 Control quality of core sandsPC 2.3 Control temperature mode for core equipmentPC 2.4 Perform maintenance and fixing for core machinesPC 2.5 Repair minor issues in machinesPC 2.6 Make cores by core boxes with machinesPC 2.7 Install complex frames with gas channels, careful finishing on flow conveyer and cores paintingPC 2.8 Control quality of cores madePC 2.9 Perform assembling and gluing of cores

3. Qualification 100402 2 – Mechanic-foundryman on machines and automatic lines * of NRK 3rd level

PC 3.1 Perform processes of preparation, regeneration and drying of core and molding sand on machines and automatic linesPC 3.2 Perform processes of molding on machines and automatic lines

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PC 3.3 Make cores on machines and automatic linesPC 3.4 Perform mold casting, casting knockout, cleaning and finishingPC 3.5 Make non-stick coatings and tracts of core and molding sand feedPC 3.6 Work using key stations of control desk, distribution switchboard and television camerasPC 3.7 Monitor the work at controlled site by pneumatic scheme, light and sound signalingPC 3.8 Provide interaction for works at sites, fill in an operation log

4. Qualification 100409 3 – Technician-metallurgist of NRK 4th level

PC 4.1 Make calculation and make a charge for casting alloys meltingPC 4.2 Appoint and control the mode of casting alloys meltingPC 4.3 Control repairs and maintenance of melting furnace and pouring potsPC 4.4 Participate in development of technological process for castings productionPC 4.5 Participate in construction development and calculation of pouring gate casting systemPC 4.6 Develop specifications of molding and core sands, select mode of castings thermal processing PC 4.7 Arrange technological processes for casting articles production applying corresponding technologies and operationsPC 4.8 Refine methods of quality improvement applying modern computer technologiesPC 4.9 Plan stages of manufacturing works accomplishment PC 4.10 Calculate basic technical and economic indexes of productionPC 4.11 Control compliance with the requirements of labor protection, fire and environmental safety when casting production

5. Qualification ******** – Assistant Foundry Production Engineer of NRK 5th level

PC 5.1 Improve and optimize operating technological processes on the basis of systematic approach to ingoing materials analysis, existing technological processes and requirements to the quality of articles acquiredPC 5.2 Apply modern program products to project castings and technology of their productionPC 5.3 With a group of experts develop necessary technological documents and participate in formation of

15

standards and normative documents, carry out certification of materials used to acquire high-quality casting PC 5.4 Arrange works on ingoing control for all ingoing materials applied in casting facilitiesPC 5.5 Control compliance with the rules of labor protection and safety, fire safety in casting facilities, develop proposals on prevention of their violationsPC 5.6 Develop technological processes for casting in temporary molds, for special kinds of casting on the basis of modern computer systems of technological processes modelingPC 5.7 Project facilities, sites, departments for casting processes applying modern technologiesPC 5.8 Develop technical documents for projected casting production equipment PC 5.9 Use methods of mathematical experiment modeling and planning, statistics methods of research data processingPC 5.10 Perform diagnostics and monitoring of equipment state applying modern means and stratification methodPC 5.11 Develop and perform improvement of technical and economic indexes of equipment operation to determine optimal resources and energy saving mode of its operation

Module nameCompetence code

(qualification)

Name of sections and topics by modules Forming competence Assessment criteria

Code of competency formed

1

1 2 3 4 5М 1. Making cores with hand molding100407 2 Core maker of hand molding *

General professional disciplinesBasics of engineering graphics.Graphic design of drawings: drawings lines, drawings formats, writing on drawings, scaling, figuring. Point, line, plane. Making a drawing by projection method.

Knowledge:– formats of drawing, types of line, their purpose, drafting typefaces, geometric constructions, scaling;– methods of projection, types of axonometric projections, constructing elevations, sections and cross-sections;

– Describes types of drawings, their formats, main inscription, dwells on the purpose of drawing lines and scaling;– explains methods of projections, types of axonometric projections, constructing elevations,

BC 1BC 4BC 6BC 7BC 10PC 1.2PC 1.5PC 2.4PC 2.5

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1 2 3 4 5Drawing transformation. Geometric planes and their intercrossing. Projection drawing. Notion of Uniform System for Design Documents (ESKD). General rules of making drawings. Drawings of standard details.

– rules of making and designing drawings.Expertise:– make drawings;– design drawings.Skills:–drawing lines and lettering;– drawing part profiles;– constructing cross-sections, simple and offset sections;– making drawings of separate parts and determining their dimensionsCompetence in:– choosing types of drawing lines;– drawing parts profiles and make inscriptions;– design technical documents.

sections and cross-sections;– characterizes elevations, sections and cross-sections– constructs complex drawings of simple models containing elevations and sections

PC 2.7PC 3.7PC 4.4PC 4.5PC 5.3PC 5.6PC 5.7PC 5.8

Basics of technical mechanics.Statics. Kinematics. Special and general cases of movement of point and solid body. Dynamics. Differential equation of movement in non-inertial and inertial frame of

Knowledge:– role and purpose of technical mechanics;– basics notions of mechanics;– major types of beam bearings;– classification of loadings;– conditions and equations of materials bodies;– fundamentals of materials

– provides geometric and analytical conditions of equilibrium for concurrent force system;– explains methodology of calculation for routine tasks applying equations of equilibrium;– dwells on the essence of


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1 2 3 4 5reference. Theory of impact. Stability of equilibrium, dynamic stability. Tension and compression of rectilinear rod. Potential deformation energy. Mechanical features of materials at tension-compression. Geometric characteristics of flat sections. Torsion and shift. Mechanical features of materials at pure shift. Potential energy of deformation. Bend. Construction of shearing force and bending moment diagrams Potential energy of deformation. Theory of stress and deformed state. Hypotheses of limiting states. Resistance to combined stress. Statistically indeterminate systems. Basic types of mechanisms. Structural analysis and synthesis of mechanisms. Kinematic

resistance;– methods of calculation of construction stress, stiffness and stability;– kinds of gears; their structure, purpose, advantages and disadvantages;– kinematics of mechanisms and machine parts connection.Expertise:– use normative and reference literature;– make calculation for tension, shear and collapsing.–make calculations for construction elements for stress, stiffness and stability.– to use rational form of bear cross-sections;– to determine gearing ratio.Skills: – applying theoretical knowledge to solve practical tasks.Competence in:– choosing methods of calculation for simple mechanical devices.

calculation method for stress, stiffness and stability of construction;– describes types of gears, their structure, purpose, advantages and disadvantages;– explains kinematics of mechanisms and machine parts connection;– makes calculation for tension, shear and collapsing;– makes all kinds of calculations for stress, stiffness and stability;– choses rational form of bear cross-sections;– determines gearing ratio.

PC 4.3PC 4.4PC 4.5PC 5.3PC 5.8

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1 2 3 4 5analysis and synthesis of mechanisms. Deviations in mechanisms. Linear equations in mechanisms.Electro technics with the basics of electronics.Electric field. Electric circuits of direct current. Single-phase electric circuits of sinusoidal current. Three-phase lines. Electric circuits of non-sinusoidal current. Transient processes. Nonlinear electric circuits. Magnetic circuit. Coil with magnetic core in alternating current circuit. Measuring electric and non-electric values. Transformers.

Knowledge:– transient processes in electric circuits;– basic electric and electromagnetic phenomena;– physical essence of electric and electromagnetic phenomena;– theoretical basics of electric engineering;– constructing and assembling laws for simple electric schemes;– engineering symbols for elements of electric circuits;– units of electric and electromagnetic values, methods and means to measure them.Expertise:– read schemes, determine the purpose of elements, analyze modes of work of electric circuits;– make simple electric schemes with series, parallel and mixed connection of elements;

– Names basic parameters of magnetic field, dwells on phenomena of electromagnetic inductance, self-inductance, and mutual inductance;– explains the purpose of electric circuit elements, names elements of electric circuit;– explains the procedure of calculation for simple electric circuits;– describes types and methods of electric measurements;– carries out calculations for simple electric circuits of direct current in accordance with the algorithm provided;– analyses circuits at series connection of inductivity and capacity;

BC 1BC 4BC 6BC 7BC 10PC 1.7PC 2.4PC 2.5PC 3.6PC 3.7PC 4.3PC 4.4PC 5.6PC 5.10

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1 2 3 4 5– make simple calculation for electrical circuits of direct and alternating current.Skills:– connect of measurement devices;– analyze work of electric circuits in routine and emergency modes.Competence in:– assemble electric circuits and check them.

– calculates series electric circuits of alternating current by the methodology provided.

Basics of standardization and metrology.Basic notions and definitions of standardization. Categories and types of standards. Metrology: basic notions, organization, scientific and methodological basics. Legal basis for ensuring single measurements.

Knowledge:– basic notions, terms and definitions in metrology, technical regulation and standardization, estimation of correspondence and product quality management;– types of standards used in professional activity.Expertise: – use information editions on standardization.Skills: – classifications of standards by types.Competence in:

– Dwells on the essence of principles and methods of standardization, explains their importance and a need to apply them in production;

– describes types of standards depending on the level of adaptation and field of use, determines type of a standard depending on the contents of requirements applied to this standard.– classifies standards by types;– uses standards applied in

BC 1BC 4BC 6BC 7BC 10PC 1.1PC 1.2PC 1.8PC 2.2PC 2.2PC 2.8PC 3.1PC 3.2PC 3.3PC 4.1PC 4.2

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1 2 3 4 5– apply standards in practical activity.

casting production. PC 4.4PC 4.5PC 5.1PC 5.3PC 5.6

Metal technology and welding.Basics of production of non-ferrous and ferrous metals and alloys. Directions of ferrous metallurgy development. Production of powders, briquetting and baking. Technologies of thermal, chemical-thermal and thermal-mechanical processing of metals and alloys.

Knowledge:– complex of production uniting ferrous metallurgy;– basic directions of development for production of steel, cast iron, non-ferrous metals and alloys– atomic-crystal metal composition;– composition and structure of metals and alloys, their classification;– types of strengthening treatment: thermal and chemical-thermal ones, surface hardening;– basic methods of metal corrosion protection.Expertise:– determine metal hardness and impact hardness;– construct curves of iron-carbon alloys cooling;– determine microstructure of

– Describes general physical, chemical, mechanical, technological features of metals, types of technological tests and physical research methods for metals;– dwells on the essence of diagrams of alloys condition, explains the principle of their construction;– reveals features of marking of carbon steels;– explains influence of thermal treatment types in the structure and features of steel;– reveals features of basic types of chemical-thermal steel treatments, explains their influence in steel features;

BC 1BC 4BC 6BC 7BC 10PC 1.2PC 2.5PC 3.4PC 4.1PC 4.2PC 5.6

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1 2 3 4 5carbon steels, cast irons, alloyed steels under microscopic test results;– read marking of steels, cast irons, non-ferrous metals and alloys.Skills: – use technical literature to solve practical tasks.Competence in:– applying theoretical knowledge to solve practical tasks.

– determines hardness of metals and alloys by Brinell tests;– makes tests for metal impact hardness;– analyses microstructure of iron-carbon alloys;– reads marking of steels, cast irons, non-ferrous metals and alloys.

Heat engineering.Theoretical basics of heat engineering. Thermodynamic processes of ideal gases. Basics of heat exchange. Basics of hydro- and aerodynamics. Heat plants of special purpose. Furnace systems. Heat exchange machines. Equipment for steam treatment. Basics on heating devices. Furnace heating devices of repairs and mechanical sites of

Knowledge:– basic laws of heat transfer, fluid and gas movement in regard of technological devices;– basic laws of chemical and physics and chemical processes and mass transfer process in regard of technological processes, machines and metallurgy equipment;– basic groups and classes of modern materials, their characteristics and fields of use, principles of choice with computer graphics methods;

– Provides general opinions on the role of heat exchange in the operation of thermal technological plants;– explains physical sense of different heat exchange types;– provides algorithm for heat flow calculation for different kinds of heat exchange;– determines field of use of modern materials by their thermophysical


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1 2 3 4 5metallurgy plants. – methods of technological

processes analysis and their influence on the quality of products acquired;Expertise:–calculate and analyze processes of external and internal heat exchange in machines of various technological purpose, choose rational temperature and heat modes for metallurgy equipment operation;– perform thermal technical calculations for heating plants;– determine consumption rates for heat, .heat conductor, fuel;Skills:– applying typical approaches to ensuring life safety and environmental cleanness;– analyzing technical economic indexes of thermal technical equipment.Competence in:– taking technological decisions to use non-waste and resources saving technologies in metallurgy;

characteristics;– makes calculation of values characterizing hydroaerodynamic flow;– analyses structure and operation principle of typical heat exchange machines, as well as their calculation methods;– makes a table of heat balance and determines unit discharge of steam, heat and electric energy.

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1 2 3 4 5– Analyzing, calculating and choosing metallurgy equipment of different technological purpose.

Special disciplinesMolding production theory and technology.Physical and chemical processes taking place when forming features of molding and core sands. Fillers of molding and core sands. Binding materials. Classification and fields of use of auxiliary materials. Physical and chemical processes taking place at sand-resin mixture setting. Physical and chemical processes taking place at setting of mixtures with nonorganic binding materials. Basic theory of formation of molding sands features. Mechanisms of casting defects occurrence and

Knowledge:– laws of choosing materials for casting molds and cores;– basic technological processes: sand production, molds and cores production, mold casting, casting knockouting, cutting and cleaning;Expertise:– determine and analyze basic physical and mechanical features of molding and core sands;– calculate basic elements and project pouring gate system to produce castings from different alloys;Skills: – projecting technological processes of castings production.Competence in:– design documents for technology of pattern equipment and castings production.

– Describes principles of formation for hardness and other physical and mechanical features of molding and core sands;– classifies fillers of moldings sands, explains their purpose and field of use;– explains the purpose of binding materials and fields of their use;– classifies molding and core sands on the basis of liquid glass;– explains basic laws of gas defects formation in castings, names methods of their prevention;– explains the purpose, construction of molding equipment major types;– explains principles of

BC 1BC 4BC 6BC 7BC 10PC 1.1PC 1.7PC 1.8PC 2.1PC 2.8PC 3.1PC 3.2PC 3.4PC 4.4PC 4.8PC 5.1PC 5.6PC 5.7

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1 2 3 4 5their prevention. Modern methods of molding sands and mixtures regeneration. Technology of hand molds and cores production methods. Technology of mechanized and automatized forming methods. Technology of core production. Basic projection of casting equipment.

casting mold production;– names methods for producing cores of any complexity;– explains modern technologies of producing wooden, metal, plastic patterns and core boxes;– determines and analyses basic physical and mechanic features of molding and core sands;– calculates basic elements and projects pouring gate system to produce castings from different alloys;– chooses and grounds the kind of sands for different alloys and casting types and dimensions.

Foundry alloys and melting.Structure and characteristics of melts. Influence of external impacts on the process of cast sections molding. Foundry characteristics of

Knowledge:– today’s understanding of structure and features of metal melts;– laws of alloys crystallization, methods of their evaluation;– interconnection of diagrams representing character of

– Dwells on fluctuation, molecular, colloid, cluster and other theories of alloy structure;– provides classification of foundry steels, chemical composition, marking and mechanical

BC 1BC 4BC 6BC 7BC 10PC 1.2PC 2.6PC 3.4

25

1 2 3 4 5alloys. Gas consumption and evolution in metals and alloys, Liquation. Metal and alloy segregation. Stress in castings. Alloys modification and alloying. Foundry steels.

crystallization, structure and alloying features of alloys.Expertise:– use diagrams of alloys condition to describe characteristics of castings crystallization, their structure and alloying features;Skills: – analysis of structure and features of carbon foundry steels.Competence in:– experimentally or by calculation determine characteristics of foundry alloys.

features of carbon foundry steels, foundry features, influence of residual elements on steel characteristics;– analyses casting characteristic of alloys;– determines gas saturation of alloys;– explains volumetric shrinkage;– analyses structure and characteristics of carbon foundry steels.

PC 4.1PC 4.2PC 4.4PC 5.1PC 5.6

Construction and technological basics of cores production at hand molding.Technological basics of cores production by hand molding methods. Specifications of core sands Control of humidity of materials and sands, dry and wet hardness, venting quality. Requirements to

Knowledge:– major technological methods applied at hand core production;– typical specifications of core sands used at hand core molding;– control methods for technological characteristics of core sands;– working conditions of cores and general requirements to them.Expertise:

– Describes technological methods of typical castings production;– classifies methods of hand molding;– provides specifications of core sands;– provides kinds of humidity control for materials and sands, dry and wet hardness, venting quality;

BC 1BC 4BC 6BC 7BC 10PC 1.1PC 1.2PC 1.3PC 1.4PC 1.5PC 1.6PC 1.7

26

1 2 3 4 5cores. – control quality of core sands

and condition of core boxes;– make cores with detachable parts, frames and structures;– make cores of ceramics for casting from special metals;– Make cores of free-running, self-hardening and cold-hardening sandsSkills: – completing cores for drying.Competence in:– making cores with hand molding.

– describes requirements to cores;– controls number of core sands and condition of core boxes;– determines humidity of materials and sands;– analyses and grounds principles of foundry mold construction;– makes cores at hand molding;

PC 1.8

Production economy, organization and planning.Arrangements of the industry in market relations system. Basics of production organization. Organization of flow and automatized production. Organization of auxiliary facilities and maintenance services. Arranging labor and salaries.

Knowledge:– composition and structure of state economic complex;– goals and motivations of production companies, their classification and structure;– goals, forms, fields of business activities;– company’s finance, finance resources, profit and gross revenue structure;– payment arrangement, composition and structure of company’s production personnel.

– Provides special and general features, procedure of founding and arrangement of production and economic activities of companies in market economy conditions;– names kinds of companies, procedure of management in state companies of different categories;– explains the notion of public budget and state


27

1 2 3 4 5Expertise: – analyze economic phenomena and processes taking place in foundry and metallurgy complex companies.

Skills: – determining economic efficiency.Competence in:– planning and arranging activity.

companies finance;–explains the essence of salary, provides general principles of labor payment, describes forms and systems of labor payment explains their special features;– calculates indexes of major production funds use, their annual price and amortized values;– makes calculation for interoperational turnover stocks and increased tact (rhythm) of flow line.

Labor protection and life safety.Legal basis of labor protection arrangement. Concept of safety culture. Arrangement of control and monitoring service to watch labor protection in a company. General sanitary and health requirements to production sites and places of work. Safety of

Knowledge:– basics of life safety and theory of risk;– Rules of safety, production sanitary norms, fire safety and labor protection.Expertise: – analyze activity of a company to detect risks in regard of safety and labor protection, as well as personnel health.

– Explains kinds of responsibility of an employer and employees for breaking legislation concerning safety and labor protection;– provides the procedure of attestation of working places under labor conditions, compulsory insurance for accidents; describes types of injuries,


28

1 2 3 4 5technological equipment. Protection of employees from radiation sources. Basics of electrosafety. Fire danger and fire protection.

Skills: – identifying dangers at production area, estimating risks of their occurrence.Competence in:– complying with norms and rules of safety and labor protection.

professional deceases and accidents at production;– analyses the procedure of making instructions for safety and labor protection;– analyses structure and principle of work of fire extinguisher and rules of its use;– complies with the rules and norms of safety and labor protection.

PC 1.8PC 2.1PC 2.2PC 2.3PC 2.4PC 2.5PC 2.6PC 2.7PC 2.8PC 2.9PC 3.1PC 3.2PC 3.3PC 3.4PC 3.5PC 4.3PC 4.7PC 4.11PC 5.4PC 5.5

Industrial training and professional practiceIndustrial training

Practical technician and mechanic training.Learning mechanical works. Choosing and using auxiliary tools, control and measurement units.

Expertise:– to perform mechanical treatment of parts;–to use the system of fits and tolerances, quality grade and roughness parameter during

– Performs mechanical works;– performs mechanical treatment of materials at turning and milling machines;

BC 1BC 3BC 4BC 5BC 7BC 8

29

1 2 3 4 5Performing technical maintenance of equipment, repairs, testing and accepting equipment. Bench-work and assembly. Learning operations of mechanical treatment of material at turning and milling machines. Complying with requirements of safety and labor protection. Maintaining order and labor culture, caring for equipment and materials.

mechanical treatment of parts;– choose and apply mechanical and measurement instrument, universal and special tools to perform mechanical works;– use equipment and material assets in efficient manner;– repair small defects in equipment operation;– take into consideration mechanical and other features of materials processed when working;– read technical documents, comply with technical conditions of work performance;– rationally arrange working place at work performance.Skills:–performing work with major types of technological equipment;– complying with requirements for safety and labor protection during bench-work and assembly.Competence in:– performing mechanical works;

– uses the system of fits and tolerances, quality grade and roughness parameter during mechanical treatment of parts;– chooses and applies mechanical and measurement instruments, universal and special tools to perform mechanical works;– repairs small defects in equipment operation;– takes into consideration mechanical and other features of materials processed when working;– reads technical documents, complies with technical conditions of work performance;– rationally arranges working place at work performance;– complies with requirements for safety and labor protection during bench-work and assembly.

BC 9PC 1.1PC 1.7PC 2.4PC 2.5PC 2.9PC 3.8PC 4.3PC 4.5PC 5.10

30

1 2 3 4 5– performing mechanical treatment of materials at turning and milling machines.

Professional practiceIndustrial training on the acquisition of worker profession “Core maker of hand molding”. Learning the structure of foundry facility, modern equipment of foundry production. Preparing students to practical work as workers. Preparing core boxes. Making big- and medium-sized cores, simples ones and of medium complexity. Making simple cores and cores of medium complexity from ceramic mixture. Assembling and gluing cores. Finishing flashes.

Expertise:–control quality of core sands and condition of core boxes;– make cores by core boxes with detachable parts, frames and structures;– make cores from ceramic mixture for castings from special metals;– make cores from free-running, self-hardening and cold-hardening sands;– fill molds, clean, glue and paint cores;– assembling core boxes, frames and structures fitting, laying wicks and cutting channels when making complex cores;– arranging cores into sets and putting them on drying plates.Skills:– analyzing technology of hand foundry cores production and practical use of materials;

– controls quality of core sands and condition of core boxes;– makes cores by core boxes with detachable parts, frames and structures;– makes cores from ceramic mixture for castings from special metals;– makes cores from free-running, self-hardening and cold-hardening sands;– fills molds, cleans, glues and paints cores;– assembles core boxes, fits frames and structure, lays wicks and cuts channels when making complex cores;– arranges cores into sets and puts them on drying plates.

BC 1BC 3BC 4BC 5BC 7BC 8BC 9PC 1.1PC 1.2PC 1.3PC 1.4PC 1.5PC 1.6PC 1.7PC 1.8

31

1 2 3 4 5–performing hand production of foundry cores.Competence in:– hand making of foundry cores.

М 2. Making cores with mechanical moulding100406 2 Core maker of machine molding *

Basics of engineering graphics.Types of products and construction documents. Sketches. Sketching details of assembly unit. Reading and detailing drawings of assembly unit. Marking materials on a drawing. Thread connections. Graphical symbols in schemes.

Knowledge:–symbols applied in principal structures, functional electric, kinematic, pneumatic, hydraulic and other schemes;– rules of making, designing and reading schemes, construction and technological documents.Expertise:– make schemes and sketches;– read drawings.Skills:–express technical thoughts in sketch, drawing, technical drawing.Competence in:– reading schemes and drawings.

– describes graphical symbols applied in functional electric, kinematic, pneumatic, hydraulic and other schemes;– provides rules of making, designing and reading schemes, construction and technological documents;– makes schemes and sketches;– reads drawings and schemes.

BC 1BC 4BC 6BC 7BC 10PC 1.2PC 1.5PC 2.4PC 2.5PC 2.7PC 3.7PC 4.4PC 4.5PC 5.3PC 5.6PC 5.7PC 5.8

Electro technics with the basics of electronics.Electric direct current machines. Asynchronous machines. Synchronous machines. Equipment for control and protection of

Knowledge:– major ways to acquire electric energy, transfer it to a distance and use in practice;– methods of rational energy consumption;– principles of electric measuring

– explains structure of direct current machines, operational principle of generators and direct current motor, as well as their field of use.– describes ways to start,

BC 1BC 4BC 6BC 7BC 10PC 1.7PC 2.4

32

1 2 3 4 5electric plants. Basics of electric drive and electric supply. Semiconductor devices: diodes, transistors, thyristos. Amplifiers. Rectifiers. Basics of digital technics.

devices operation.Expertise:– calculate and project simple schemes of electric circuits in accordance with technical requirements;– choose electric devices by their purpose, make electric measurements.Skills:– reading characteristics and purpose of electric deviceCompetence in:– making analysis of performance and changing equipment with low efficiency to the one with high efficiency.

reverse and control speed of rotation and braking of direct current motors;– explains structure, operation principle and purpose of switching and protection units;– describes schemes of electric supply for different kinds of consumers, purpose, structure and operation principle of electric measuring devices;– analyses operation of manual or automatic switching device;–chooses electric measuring devices by their purpose, makes electric measurements.

PC 2.5PC 3.6PC 3.7PC 4.3PC 4.4PC 5.6PC 5.10

Basics of standardization and metrology.Variety of measurement tasks. Classification of measurements by measurement types. Methods of measuring and

Knowledge:– system of geometric parameters accuracy;– methodology of fits and tolerances calculation;– types, purpose and operation principle of technical

– Explains graphical scheme of tolerance bands and marks of deviation limits in operational drawings of products;– characterizes types of tolerances, quality grade,

BC 1BC 4BC 6BC 7BC 10PC 1.1PC 1.2

33

1 2 3 4 5control. Means of measuring and control. Applying calculating devices in means of measurement. Requirements of modern metrology. The role of metrology in improving the quality of products, services and production. Methods and means of control for slick cylinder and bevel, thread, key and slip joints, wheel and worm gears. Deviation of form and surface position and control over them. Role of technical norms and standardization in ensuring product quality. Estimation of product quality level. Making up and developing international standards ISP series 9000. Legal basis of technical norms and standardization. State monitoring over compliance with standards and over

measurement means.Expertise:– determine dimensions, deviations and fits of parts and their joints;– determine clearance and interference limits of joints;– use technical measurement means;– control indexes when checking product quality at all stages of production;– classify types of defects and correlate them with a certain group and technological stage of production where they could have appeared.Skills: – using the list of acceptable deviations decreasing quality indexes.Competence in:– using standards indications;– applying necessary standards and other standardization documents to solve the tasks set.

level of detail production accuracy – accuracy quality grade, maximum and minimum clearances and interferences;– describes roughness grades, roughness indexes and symbols to indicate surface roughness;–

PC 1.8PC 2.2PC 2.2PC 2.8PC 3.1PC 3.2PC 3.3PC 4.1PC 4.2PC 4.4PC 4.5PC 5.1PC 5.3PC 5.6

34

1 2 3 4 5measurement means.Metal technology and welding.Foundry characteristics of alloys, constructing and making castings. Basics of welding production. Classification and characteristics of welding methods. Equipment for gas welding. New methods of pressure welding without melting. Welding cast iron, non-ferrous metals and alloys, carbon and alloyed steels. Hard-surfacing technology. Weld seam quality control. Basics of metal cutting. Treatment on turning, drilling, milling and other machines.

Knowledge:– basic directions and perspectives of melting and pressure welding development;– physical, chemical, mechanical and technological characteristics of metals and alloys;– ways to determine basic mechanical characteristics of metals;– principles of making diagrams for alloys condition;– types and purpose of construction and instrumental steels, including reinforcement steels;– qualification and marking of steels, cast irons and non-ferrous alloys based on aluminum and copper.– filed of use for ferrous and non-ferrous metals and alloys;– basics of steels, cast irons and non-ferrous metals production technology;– ways to treat metal by casting (into sand and special molds),

–Names ingoing materials necessary to acquire cast iron, describes their preparation for casting;– describes modern methods of steel casting;–names general development trends for production of non-ferrous metals and alloys;– describes basic foundry alloys, casting machines, technology of getting casts in temporary sand and clay molds, ways of foundry molds and cores production, technology of special way of casting.;– reveals the essence of welding, welding joint, brazing, provides classification of welding by physical, technical and technological characteristics;– describes major tendencies of welding joints

BC 1BC 4BC 6BC 7BC 10PC 1.2PC 2.5PC 3.4PC 4.1PC 4.2PC 5.6

35

1 2 3 4 5pressure, cutting;– theoretical basics of metal welding and cutting;– sequence of welding works performance;– welding works in construction and mounting production;– technology of electric-arc welding and contact welding;– structure and operation principle of welding devices for hand arc welding, of spot-welding machine.Expertise:– appoint modes and perform major operations of carbon steels thermal treatment;–Provide quality control for weld seal by one of physical methods.Skills:– reading symbols of welding joints in a drawing;Competence in:– determining type of carbon steel and cast iron by their structure.

and weld seams, methods of welding;– analyses structure and operation principle of welding machines for hand arc welding;– appoints modes of steel hardening and temper, analyses microstructure and hardness of steel before and after thermal treatment;– provides quality control of a weld seam by ultrasound (magnetic) method.

Special disciplines

36

1 2 3 4 5Foundry alloys and melting.Cast iron. High-strength cast iron with a spheroidal graphite and vermicular form. Non-ferrous casting alloys. Copper-based alloys. Aluminum alloys. Casting alloys based on magnesium, titanium, zinc and nickel.

Knowledge:– Types of alloy heat treatment;– Equipment used and the physics and chemistry of melting processes;– Casting, physical, mechanical and performance properties of iron-carbon and non-ferrous metals and alloys, as well as their application.Abilities:– To determine the mode of alloy heat treatment;– To analyze the causes of casting defects and to develop ways to eliminate them;– To calculate the required composition of the charging material.Skills:– To choose the effective melting equipment, modes and parameters of melting for the particular types of alloys.To be competent means:– To choose the alloy for the particular part with regard to its operating conditions.

– One describes characteristics of mechanical, operational and casting properties of the alloys, justification of the choice of alloying elements;– One describes characteristics of the physical and chemical processes in melting furnaces while melting cast alloys, thermodynamics of the melting process, and features of the processes of melting cast alloys;– One analyses the structure and properties of the steels and alloys with special properties;– One characterizes methods for producing high-strength of cast iron;– One analyses the structure and properties of the alloys based on magnesium, titanium, zinc and nickel.

BC 1BC 4BC 6BC 7BC 10PC 1.2PC 2.6PC 3.4PC 4.1PC 4.2PC 4.4PC 5.1PC 5.6

37

1 2 3 4 5Design and technological basis of the production of cores with machine molding.Design of core boxes. Design and principles of operation of core machines. Formulation of mixtures for machine core molding in the production of castings. The control methods of technological properties of core mixtures. The technology of core manufacturing and requirements for the cores.

Knowledge:– the design and principle of operation of core boxes;– the construction and the principle of operation of core-making machines;– the compositions of the core mixtures and other auxiliary materials used in the manufacture of cores as well as the requirements for them;– the methods of determining physical and mechanical properties and quality of core sand mixtures;– the procedure for manufacturing cores using machines and automatic machines of various types.Abilities:– to perform maintenance and adjustment of core-making machines;– tp performs the check of the quality of core sand mixtures;Skills:– to control the quality of the finished cores.

– One describes the construction, the basic principles of design and operation of core boxes, jigs and tooling;– One explains the construction and the principle of operation of the maintaining core-making machines and automation devices, the rules of their control;– One describes the compositions of core mixtures and other auxiliary materials used in the manufacture of cores as well as the requirements for them;– One describes the methods of determining physical and mechanical properties and quality of core sand mixtures;– One describes the technology of core manufacturing, modes of curing and core drying,


38

1 2 3 4 5To be competent means:– to produce the cores using core boxes on the machines.

rules of placing of the gas outlets;– One performs maintenance and produces adjustment of core-making machines;– One performs the check of the quality of core sand mixtures;– One produces the cores using core boxes on the machines;– One controls the quality of the finished cores.

Professional practiceIndustrial training for the acquisition of worker profession “Core maker of machine molding”.Students’ preparation for practical work as laborers. Maintenance and corrective adjustment of core-making machines and automatic machines. Preparation of core boxes. Quality control of core sand mixtures. Production of cores of

Abilities:– to control the quality of core sands and conditions of core boxes;– to perform maintenance and adjustment/setup of core making machines and automatic machines;– to carry out the production of cores according to the core boxes;– to control the quality of manufactured cores;

– One controls the quality of core sands and conditions of core boxes;– One performs maintenance and adjustment/setup of core making machines and automatic machines;– One carries out the production of cores according to the core boxes;– One controls the quality of manufactured cores;

BC 1BC 3BC 4BC 5BC 7BC 8BC 9PC 2.1PC 2.2PC 2.3PC 2.4PC 2.5PC 2.6

39

1 2 3 4 5simple and medium complexity according to the core boxes using core-making machines and automatic machines. Finishing, painting, and laying of cores for drying.

– to carry out the assembly and gluing of cores.Skills:– to analyze the technology of machine manufacturing of foundry cores and of practical application of materials.To be competent means:– to carry out the process of foundry cores machine manufacturing.

– One carries out the assembly and gluing of cores.

PC 2.7PC 2.8PC 2.9

М 3. Preparation of molding and core mixtures, manufacture of molds and cores using the machines and automatic lines.100402 2 –Mechanic-foundry man on machines and automatic lines *

Special disciplinesEquipment of foundry shops.The equipment of foundry shops of the general purpose. The equipment for mechanization and automation of charge-preparation and melting compartments. Mixture preparation equipment. Castings processing equipment.

Knowledge:– Various machine types configuration, combined in technological groups and are ensuring the implementation of main foundry manufacturing technology cycles;– the rules of foundry machines maintenance and operation.Abilities:– to analyze the construction of the equipment of foundry shops.Skills:– to choose the equipment of foundry shops in accordance to its purpose.

– One describes the structure, function and operation of equipment for the preparation, storage and transportation of the original molding materials;– One explains the principle of operation of the equipment for storage of the charge and melting compartments;– One classifies blowing machines and describes the range of their applications at the foundry

BC 1BC 4BC 6BC 7BC 10PC 2.4PC 2.5PC 2.6PC 2.7PC 3.1PC 3.2PC 3.3PC 3.4PC 3.5PC 4.3PC 4.4

40

1 2 3 4 5To be competent means:– to solve engineering problems related to the operation and maintenance of foundry equipment.

shops;– One explains the principle of operation and design of mixture preparation equipment;– One describes the principle of operation of the moulding and core-making equipment;– One explains the principle of operation and design of equipment for processing of castings;– One analyzes the design, purpose and principle of operation of the equipment for the preparation, storage and transportation of the initial molding materials;– One analyzes the design, purpose and principle of operation of equipment for storage of the charge and melting compartments;– One analyzes the design, operation and control of molding and core

PC 4.5PC 4.7PC 5.1PC 5.6PC 5.7PC 5.8PC 5.10

41

1 2 3 4 5equipment;– One analyzes design and principle of operation of the equipment for processing of castings.

Professional practiceIndustrial practice for acquisition of the worker profession “Mechanic-foundry man on machines and automatic lines”.Mastering of the techniques of technological equipment maintenance. Preparation of students for practical work as workers. Running of process of preparation, regeneration and drying of molding materials and sand mixtures, as well as molding. Production of foundry molds and cores. Implementation of interaction of works at the sites. Running of the operating log.

Abilities:– to identify and rectify faults in functioning of equipment being in service;– to carry out the setup and control / regulating of the machines and automatic lines;– to run the process of molding and core sand mixtures preparation;– to control the quality of molding sand mixtures and cores;– to produce foundry molds;– to produce cores using machines and automatic lines.Skills:– to run machines and automatic lines designed for castings production.

To be competent means:

– One identifies and rectify faults in functioning of equipment being in service;– One carries out the setup and control / regulating of the machines and automatic lines;– One runs the process of molding and core sand mixtures preparation;– One controls the quality of molding sand mixtures and cores;– One produces foundry molds;– One produces cores using machines and automatic lines.

BC 1BC 3BC 4BC 5BC 7BC 8BC 9PC 3.1PC 3.2PC 3.3PC 3.4PC 3.5PC 3.6PC 3.7PC 3.8

42

1 2 3 4 5– to carry out the process of molding and core sand mixtures preparation, as well as the process of producing molds and cores.

М 4. Organization and participation in the conduction of the technological process of castings production.100409 3 – Technician-metallurgist

General professional disciplinesRecords management in state language.Document classification and details. Role of documents and their significance. File Register and paperwork management. Rules of document drafting. Paperwork in the Kazakh language: on staff, management activities, information and help. The process of paperwork management using technical means.

Knowledge:– National standards and normative-legal acts for the document management;– Record keeping system and the procedure for record keeping at the organisation;– Unified forms of primary accounting documents by the profile of the professional activities;– The rules of preparation and execution of organisational and administrative documents;– The requirements for the preparation and execution of the main types of administrative documents;– The general rules of the organization of work with incoming, outgoing and internal documents;

– One describes the types of documents and reveals their significance, as well as classifies the administrative documents;– One sets out the requirements for the execution of the documents forms;– One describes the structure of the documents details, characterizes their types, purpose and location on the document;– One sets out the basic principles of the document management, the requirements for admission, registration, and execution of the internal and external documents, as well as for the preparation of the

BC 1BC 4BC 6BC 7BC 10PC 4.1PC 4.4PC 4.5PC 4.6PC 4.7PC 5.3PC 5.4PC 5.11

43

1 2 3 4 5– The rules of the current document storage;– The procedure for the preparation of documentation for long term storage.Abilities:– To use the normative acts and methodological materials on records management and archive-keeping, the standard of the unified system of the organisational and administrative documents;– To draw up the details according to the layout key;– To fill in primary accounting documents by the profile of the professional activities;– To keep records of incoming and outgoing documents;– To prepare the documentation for long term storage.Skills:– To prepare and execute various types of organisational and administrative documents and copies thereof.To be competent means:

register of the documents to be sent;– One sets out the procedure for operative storage of the documents, as well as for processing of the cases to be transferred to the archive;– One develops the layouts of the general template as well as of the template for letters of the specific organisation;– One develops and prepares the management letter;– One develops and prepares the order for the personnel;– One keeps records of incoming, outgoing and internal documents in the registration log and on the registration-control cards;– One uses technical methods when working with documents in the national language.

44

1 2 3 4 5– To draw up and execute personal and official documents in the state language.

Basics of computer technology in the industry.Information systems for professional use. Databases as display system of business information. The system of standards for information technologies of business processing. Standards for electronic documents. Protection of business information. Using the application software to perform the complex calculations. The technologies of creation and processing of textual information. The technologies of creation and processing of graphic and multimedia information.

Knowledge:– Trends in the development of information technologies;– Basics of building, the perspectives of local and global computer networks development, network technologies for information processing;– Ways of presenting and processing of technology, storage and transmission of information;– Classification of the personal computer software;– Numerical methods of solution and principles of mathematical simulation of applied problems;– The rules for using the hardware and software of the personal computer, systems and networks;– The purpose and possibilities of graphic and text editors, spreadsheets, and database management systems for the

– One describes the purpose and capabilities of the information systems, their types, basic objects and attributes, the technology of distributed processing and the types of the software in use;– One sets out basic requirements for the design of electronic documents, describes the technologies required to obtain the template of the electronic document of the desired standard, the basic principles of standardization of computer networks;– One clears up the classification of and criteria for selecting application software for use in the professional activities, explains the

BC 1BC 4BC 6BC 7BC 10PC 4.1PC 4.4PC 4.5PC 4.6PC 4.7PC 4.8PC 4.9PC 4.10PC 5.1PC 5.2PC 5.3PC 5.4PC 5.6PC 5.7PC 5.8PC 5.9PC 5.10

45

1 2 3 4 5creation of technical documentation, applied in professional activity;– The methods of information protection.Abilities:– To use standard and application software of the personal computer;– To apply modern methods of computer-aided designing;– To create electronic documents.Skills:– to work using application programs.To be competent means:– To search for information on the Internet, to use e-mail and modern information technologies.

functions of the application MS Excel when performing complex calculations;– One explains the technologies of creation and processing of graphic and multi-media information, of developing the presentations, web pages and web sites;– One develops the models of tables of the reference, planning and accounting information, justifies the choice of the key field, performs the data input and correction in datasheet view;– One organizes the search of information on the Internet, applies it, and develops the requests for data modification in the system;– One develops the templates of business

46

1 2 3 4 5information using the standards of electronic documents;– One uses the possibilities of the application MS Excel to perform the calculations of the production programs of the structural sub-division of the organization.

Special disciplinesTheory and technology of foundry production.The technologies of finishing operations of castings production. Environmental aspects of castings manufacturing technologies.

Knowledge:– The methods of casting quality control;– The standards in the field of materials and technologies of casting processes.Abilities:– To organize the technological process of castings manufacturing, to control their quality providing minimum prime cost;– To analyze the prospects for the development of the technology of foundry production as well as of the necessary processes for

– One explains the fundamentals of the technology of casting of foundry forms;– One explains the principles of grading of castings and methods reoperation;– One specifies the main types of harmful substances generated in the period of mixtures manufacture and production of foundry molds and cores;– One analyzes the main

BC 1BC 4BC 6BC 7BC 10PC 4.4PC 4.8PC 5.1PC 5.6PC 5.7

47

1 2 3 4 5obtaining of new materials and equipment.Skills:– To choose the effective criteria for technology development and equipment design to ensure casting meets the demands of today’s foundry production.To be competent means:– To improve and optimize the current technological processes on the basis of the systematic approach to the analysis of raw materials, existing technological processes and requirements to the quality of products produced.

trends occurring in the world industry and the role of the foundry production in these processes;– One designs the technology of castings production;– One designs the technological equipment.

The systems of automated designing and simulation of foundry processes.The fundamentals of computer aided design (CAD). The use of CAD in foundry production. The design of the cast parts. CAD systems. Automation of designing of casting technology. The systems of computer simulation of

Knowledge:– Modern systems of computer simulation of casting processes;– Casting processes simulation fundamentals in systems ProCast, Polygon, LVMflow etc.;– The possibilities of integrated systems designing and engineering analysis of strength and dynamics of the structures;– The advanced technologies of

– One describes the structure of the designing process, the procedure of formation of the production database;– One describes the choice of the rational design of the casting detail, the types of analysis performed using the software packages ANSYS, NASTRAN,


48

1 2 3 4 5casting processes. The system of computer modeling "ProCast". The system of computer simulation "Poligon". Software and innovative technological processes of foundry equipment production. Rapid prototyping technologies.

rapid prototyping, designed to manufacture foundry and pattern equipment.Abilities:– To create three-dimensional solid models in CAD;– To design a casting mold.Skills:– To develop the technological processes using the simulation systems Polygon, ProCast, LVMflow etc.To be competent means:– To apply the acquired knowledge in the design and development of foundry equipment and machinery.

COSMOS;– One specifies the modules of the system "Polygon", sets out the principles of solving the heat problem, hydrodynamics, the form completing;– One describes the main modules of the system "ProCast". Specifies the capabilities of the modeling system of foundry processes;– One describes the technology of rapid prototyping "Rapid Prototyping", laser stereo lithography, the technology of selective laser sintering and layer-by-layer manufacturing of the objects, etc.– One designs the casting mold;– One creates a three-dimensional solid model in CAD;

PC 5.9

49

1 2 3 4 5– One analyzes the results of simulation and develops technology to manufacture qualitative casting in the system "ProCast".

Casting tooling design.Development of technological process of models manufacture. Design and manufacture of models. Manufacture of wooden models. Manufacture of plastic polymers models. Metal casting patterns. Core boxes design. Foundry flask design. Designing and arrangement of the press molds for injection molding. Designing and arrangement of the non-pressure chill mold. Designing and arrangement of ingot molds for centrifugal casting.

Knowledge:– Modern materials and tooling structures for castings manufacture;– The calculating methods for basic tooling parameters;– The distinctive features of tooling design for hand and machine molding;– Flask designs for different molding machines and automatic lines;– Mechanisms of press molds for injection molding, their design and parts that make up the mechanisms.Abilities:– To design the tolling and its main elements.Skills:– To analyze parts’ manufacturability for particular

– One classifies the model tooling: according to the type of the material, the method of manufacturing of the mold and cores, the sizes of the casting, accuracy of manufacturing and strength, the complexity of the configuration of the casting and the nature of the pouring alloy;– One sets out the procedure for manufacturing a model-pattern, pro models and industrial models;– One specifies the materials for the manufacture of pro models, working models as well as release agents;


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1 2 3 4 5molding method.To be competent means:– Carry out drawings of various parts of tooling using standard software packages.

– One describes the structures and main elements of the core boxes;– One describes the rules for designing of iron and steel flasks;– One describes the shaping and structural parts and the mechanisms of press-molds;– One designs the metal models;– One designs the core boxes;– One analyzes the arrangement of the press-molds of injection molding.

Equipment of foundry shops.The equipment for special foundry methods. Hoisting apparatus of foundry shops. Transport facilities of foundry shops. Modern tendencies in the development of foundry

Knowledge:– Calculation methods of foundry equipment main assembly units;– The principles of designing of mechanized and automated complexes on the basis of foundry equipment of software manipulators and robots;

– One classifies chill casting machines based on the main features and explains the principle of operation and mechanism of locking the chill mold;– One gives the examples of automated systems of control of the process of


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1 2 3 4 5equipment constructions. – The modes and conditions of

operation of lifting and handling equipment;– The methods of diagnosing the equipment conditions.Abilities:– To analyze the construction of the conveyors of various structures and to perform the calculation of their draft force;– To carry out technical and economic analysis of different options for foundry shops equipping with progressive foundry machines.Skills:– To perform the layout of equipment for the various processing stages in accordance with the required technology of castings manufacturing.To be competent means:– To solve engineering problems related to the development and improvement of new foundry equipment.

injection molding as well as automated complexes of injection molding;– One specifies the equipment for the manufacture of investment patterns;– One describes the construction of centrifugal machines;– One describes the equipment for obtaining the sand-resin mixtures, as well as the manufacture of shell molds and shake-out of the castings out of them;– One outlines the areas of application of transport devices and the peculiarities of operation;– One analyzes the design of the pressing and locking mechanisms of the equipment of injection molding and performs the calculation of the parameters;– One analyzes the design

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1 2 3 4 5of conveyors of various designs and calculates their draft force.

Economics, organisation and planning of production.The tax system of the Republic of Kazakhstan in the context of market economy.Organization and planning of new equipment development. Organization of intra-factory planning. Making up of a business plan. Fundamentals of accounting and analysis of industrial and economic activities within the organisations. Enterprise management. Innovations marketing. Innovations planning and management. The procedure of business structures formation.

Knowledge:– the mechanism of organisation’s management;– the planning of organisation’s economic activity;– intrafactory economic relations;– Innovations organization and planning;– the products quality and competitiveness management;– the organisation’s investment activity;– the assessment of efficiency of the organisation’s activity: indicators, calculation methods, spheres of application.Abilities:– to make manufacturing and administrative decisions in order to achieve maximum results as for the activity of the organisation of foundry and metallurgic industry;– to carry out planning of

– One describes the activities, the procedure of the new organization formation;– One specifies the procedure of developing the business plan for the organization, as well as its sections;– One explains the procedure for planning of the organization's requirement of material resources, and identifies the ways of their saving and rational use;– One describes the method of calculation of indicators of working hours and the ways to increase the productivity;– One explains the calculation of the estimate of expenses for the production of goods,


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1 2 3 4 5organisation’s activity.Skills:– to learn new forms of innovations and business activity.To be competent means:– to carry out planning of manufacturing activity.

works and services, as well as costing of products, works and services;– One explains the system of indicators to improve the economic efficiency of production;– One describes the methodology of analysis of economic activity;– One calculates the economic efficiency of new technology implementation and investments;– One performs planning of the production activities.

Safety and health management.Hazardous and harmful industrial chemical factors. Safety and occupational health requirements, workplace policy in chemical laboratories. Safety insurance during

Knowledge:– the means and methods to improve safety, ecological compatibility and sustainability of technical means and technological processes;– the safety requirements while working with main and auxiliary equipment;

– One uses sanitary and hygienic and sanitary and technical norms in the organization of processes and production, used materials, equipment, machinery and other factors;– One explains the


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1 2 3 4 5repair and cleaning works. Legal and organisational issues relating to occupational health and safety principles.

– the operation of the system of staff health ensuring and occupational safety of different organisations.Abilities:– to measure and assess the parameters of working micro environment, the level of dust and gas pollution, noise, vibration, and illumination of working places.Skills:– to control electromagnetic, ionizing and thermal radiation as well as the level of negative impacts for their compliance with regulatory requirements.To be competent means:– to ensure the compliance of the safety rules and labor protection;– to develop the measures on safety and labor protection.

influence of microclimate on the workers, describes the means of providing the normative parameters of the microclimate;– One defines the safety of the technological process and equipment, sets out the general requirements to them;– One sets out safe practices in the operation of the processing and manufacturing equipment;– One determines the microclimate in the workplace, and prepares the measures on elimination of discrepancies;– One performs the calculation of the ventilation of industrial premises;– One uses the rules of safe operation of equipment with radiation.

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1 2 3 4 5Professional practice

Industrial practice in designing and manufacturing of the technological tooling.Mastering of the technology of production of wooden foundry and pattern equipment using numerically controlled machines. Mastering of the technology of production of wooden foundry and pattern equipment out of polymeric materials using numerically controlled machines. Mastering of the technology of production of wooden foundry and pattern equipment out of liquid two-component polymeric materials.

Abilities:– to implement the main steps of foundry and pattern equipment manufacturing using numerically controlled machines;– to manufacture wooden foundry and pattern equipment;– to manufacture foundry and pattern equipment made out of polymeric materials;– to manufacture foundry and pattern equipment out of liquid two-component polymeric materials.Skills:– to develop the design/structure of core boxes and pattern equipment (tooling);– to develop the control software programs for production of foundry and pattern equipment, taking into account the principles and the sequence of processing of wooden materials and polymeric materials using numerically controlled machines;– to carry out the preparation of

– One implements the main stages of manufacturing of foundry pattern equipment using numerically controlled machine tools;– One manufactures wooden foundry and pattern equipment;– One manufactures foundry and pattern equipment out of polymeric materials;– One manufactures foundry and pattern equipment out of liquid two-component polymeric materials;– One develops the design of core boxes and pattern equipment;– One develops control software programs for manufacturing of foundry and pattern equipment taking into account the principles and the sequence of processing of wooden

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1 2 3 4 5

two-component liquid polymer materials and manufacturing of foundry and pattern equipment out of them.To be competent means:– to design and manufacture the technological tooling.

materials and polymeric materials using numerically controlled machines;– One performs the preparation of two-component liquid polymer materials and manufacturing of foundry and pattern equipment out of them.

Technological practice.Practicing the theoretical and practical knowledge acquired by students while studying general and special disciplines. Participation in the work procedures being completed by the foundry shop workers. Mastering of the principles and skills of foundry shop departments management. The acquisition of practical skills concerning the development of casting production technology as well as the necessary technological

Abilities:– to provide the efficient use of equipment and material resources;– to maintain the established order of foundry engineering technological processes;– to rectify the simplest foundry shop equipment faults / malfunction;– to plan the working day schedule at the working site;– to execute the orders for work performance;– to fulfill the working duties at the working place;– to organize the planned preventive maintenance;

– One provides the efficient use of equipment and material resources;;– One maintains the established regime of technological processes of foundry production;– One rectifies the simplest foundry shop equipment faults / malfunction;– One plans the working day schedule at the working site;– One executes the orders for work performance;– One fulfills the working duties at the working place;– One organizes the

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1 2 3 4 5documentation. Preparation of the documents for the equipment maintenance and repair. The production of work performance order. Briefing at the workplace. Planning of the day schedule and the analysis of the site work performance. The analysis of labour payment types. The organization of the planned preventive maintenance.

– to make photos of the working day; to process these photos.Skills:– to exercise control over work performance following the current provisions and rules concerning occupational safety, industrial hygiene and fire protection;–to perform work using the main types of technological equipment of a foundry shop independently;–to hand out the tasks to those who are in charge;– to exercise briefings at the workplace;– to maintain the relations with related engineering and technical personnel;– to supervise the staff performing work at the site.To be competent means:– to organize and participate in the technological process of castings manufacturing.

planned preventive maintenance;– One makes photos of the working day and processes these photos;– One exercises control over work performance following the current provisions and rules concerning occupational safety, industrial hygiene and fire protection;One hands out the tasks to those who are in charge;– One exercises briefings at the workplace;– One maintains the relations with related engineering and technical personnel;– One supervises the staff performing work at the site.

PC 4.10PC 4.11PC 5.1PC 5.4PC 5.5PC 5.6

М 5.Designing of technological

Special disciplinesAutomatic lines and systems.

Knowledge:– the principles of construction

– One describes the classification, composition

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1 2 3 4 5processes and technological equipment, ensuring the activities of the foundry production ******* –Assistant Foundry Production Engineer

The methods of analysis, calculation and design of automatic lines and systems. Automatic foundry lines. Automated mixture-making complexes and systems of cores manufacturing. Automated systems for metal melting and casting. Automation of casting manufacturing finishing operations. The systems of heat recovery of flue gas and dust and gas treatment of foundry shops.

and development of automated systems, automated lines and systems;– the main technical characteristics, layout and design features of automated lines and systems used in modern foundry production;– the organization of automatic transfer lines and automated equipment for molding castings of special methods;– the methods of calculation and estimation of basic economic, technological, and exploitation parameters of automated lines and systems.Abilities:– to analyze the structure, composition and technological capabilities of automated-bath complexes, automated lines and systems.Skills:– to assess economic, technological and technical parameters of the automated lines and systems.

and arrangement, as well as the optimization of the structure, the peculiarities of design and production of foundry automatic lines;– One explains the advantages and disadvantages, as well as the diagram of the manufacturing process of molds using air-pressing method;– One specifies the classification and varieties of methods, the organization of automatic lines of pulse forming;– One describes the organization of the automated complexes of permanent mold casting, the machines and automated systems for injection moulding;– One describes modern casting complexes;– One analyzes the design

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1 2 3 4 5To be competent means:– to calculate and design automated systems, automatic lines and systems for the implementation of the basic processes of foundry production.

and the principle of operation of automatic molding lines;– One analyzes the design and the principle of operation of automatic lines for the manufacture of molds and cores;– One analyzes the design and the principle of operation of automatic casting systems.

Automation of foundry production.Automated control, monitoring and regulation of industrial processes. Automation systems. Automatic control systems (ACS). The systems of automatic control, regulation, remote control, automatic protection and block. The converters, actuators and regulators in automation systems. Control and measurement devices in foundry

Knowledge:– the operation principles of devices aimed at automated control, automated protection and blocking remote control regulation, converters, control and measurement devices in foundry processes and equipment automation;– the requirements to be met by modern automated production;– the principles of automated complexes, lines and systems of construction and design;– the basic specifications, layout and design characteristics of

– One analyzes the local, integrated and automated systems of automation;– One describes the systems of automatic control and alarm system, remote transmission and follow-up servo systems;– One describes the automation of the process of the preparation of sand;– One describes the features of automation of the core-blowing machine;– One specifies the automation of the process


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1 2 3 4 5automated systems. Automation of mixture preparation processes. Automation of molds and cores manufacturing processes. Melting and casting automation. Automation of castings shake-out and cleaning processes. Special foundry methods automation. Methods and tools for environmental conditions control. Automated lines and systems. Methods of analysis, calculation and design of automated lines and systems. Automated molding lines. Automated mixture preparation complexes and cores manufacturing systems. Automated complexes for metal melting and castings manufacturing completion operations performance.

automated lines and systems used in modern foundry manufacturing;– the methods of calculation and evaluation of basic economic, technological and operational parameters of automated lines and systems.Abilities:– to develop functional block diagrams featuring foundry processes and equipment automation;– to assess economic, technological and technical parameters of automated complexes, automated lines and systems.Skills:– to analyze the structure, composition and technological capabilities of automated complexes, automated lines and systems.To be competent means:– to calculate and design automated complexes, automated lines and systems aimed at the

of filling of forms on the casting conveyor;– One identifies the automation of the processes of foundries scarfing;– One calculates the process of the automation of molding materials preparation;– One calculates the process of the automation of metals casting;– One calculates the process of the automation of die casting machines.

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1 2 3 4 5implementation of basic technological processes of foundry production.

Professional practicePre-diploma practice.Practicing the principles of production organization and management, the analysis of economic parameters of foundry shop and its sites operation as well as measures aimed at improving the efficiency of their functioning. The familiarization with / mastering of software systems used for technological equipment design, castings engineering, gating systems improvement, calculation, analysis, optimization of foundry manufacturing facilities operation. Collection of all necessary materials and documents in order to make a diploma project (to write a diploma paper).

Abilities:– to read technical and technological documentation;– to meet the requirements specified in technological instructions;– to make the calculation of the production prime cost;– to analyze the economic indicators of foundry shop and its sites operation.Skills:– to follow the requirements of health and safety at the working place;– to complete the documents according to the specified requirements.To be competent means:– to design the technological processes as well as the technological tooling, and to ensure the activities of the foundry production.

– One reads technical and technological documentation;– One meets the requirements specified in technological instructions;– One makes the calculation of the production prime cost;– One analyzes the economic indicators of foundry shop and its sites operation;– One follows the requirements of health and safety at the working place;– One completes the documents according to the specified requirements;– One designs the technological processes as well as the technological tooling, and ensures the activities of the foundry production.

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CONTENT AND STRUCTURE OF EDUCATIONAL PROGRAM

The name of cycles and disciplines Competencies deliveredGeneral professional disciplines

Basics of engineering graphics.Drawing graphic design: drawing lines, drawing formats, drawing annotation, scale drawings, dimensioning. Point, line, plane. Drawing using projection method. Drawing transformation. Geometric surfaces and their intersection. Projection drawing. The concept of the Uniform system of design documentation (ESKD). General rules of drawings. Drawings of standard parts. Types of products and design documents. Sketches. Assembly unit sketching. Reading and detailing of assembly unit drawings. Material designation. Threaded joints. Scheme legend and graphic symbols.

Knowledge:- Drawing formats, types of lines, their purpose, drawing fonts, geometrical constructions, the scale;- Projection methods, axonometrical projection types, their plotting, sections and cross sections plotting;- Symbols used in the basic block diagrams, functional block diagrams, electrical, kinematic, pneumatic, hydraulic, and other diagrams;- Rules of producing, designing and reading drawings, diagrams, design and technological documentation.Abilities:- Produce drawings, diagrams, and sketches;- Read and design drawings;- Communicate the idea using sketches and drawings.

Basics of technical mechanics.Statics. Kinematics. General and specific motion of a point and rigid body. Dynamics. The differential equation of motion in inertial and non-inertial reference frames. Theory of impact. Equilibrium and motion stability. Tension and compression of a straight bar. Strain energy. Mechanical properties of materials under tension and compression. Geometric characteristics of flat sections. Shear and torsion. The mechanical properties of materials under pure shear stress. Strain energy. Bend. Shear and bending moments’ diagrams. Strain energy. Stress and strain state theory. Limit state hypotheses. Combined stress resistance. Statistically indeterminate system. The

Knowledge:- The role and importance of theoretical mechanics;- Basic notions of mechanics;- Main types of bearings of beams;- Classification of loads;- The conditions and the equation of equilibrium of material bodies;- Main points of structural resistance;- The methods of calculation for strength, rigidity and stability of structures;- Types of transmissions; their structure, function, advantages and disadvantages;- Kinematics of mechanisms, the connection of machine parts.Abilities:- Use of normative and reference books; - Make calculations for compression,

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The name of cycles and disciplines Competencies delivered

main types of mechanisms. Structural analysis and synthesis of mechanisms. Kinematic analysis and synthesis of mechanisms. Fluctuations in mechanisms. Mechanisms’ linear equations.

shear and crushing;- Make calculations of structural elements for strength, rigidity and stability;- Choose a rational cross-sectional shape of beams;- Determine the reduction ratio.

Electro technics with the basics of electronicsElectrical field. Electrical DC circuit. Single-phase sinusoidal current circuits. Three-phase circuits. Non-sinusoidal current circuits. Transients. Non-linear circuits. Magnetic circuit. Electromagnetic coil in AC circuit. Measurements of electrical and non-electrical quantities. Transformers. Direct current machines. Asynchronous machines. Synchronous machines. Equipment for control and protection of electrical installations. Basics of electric drive and power supply. Semiconductors: diodes, transistors, thyristors. Amplifiers. Rectifiers. Basics of digital technology.

Knowledge:- The main methods of obtaining, transmission at a distance and the practical use of electric energy;- Methods of rational energy use;- Transition processes in electrical circuits;- Basic electrical and electromagnetic phenomena;- Physical nature of electric and electromagnetic phenomena;- Theoretical foundations of electrical engineering;- Patterns of construction and assembly of simple electrical circuits;- Conditional graphic designations of elements of electrical circuits;- Units of electrical and electromagnetic quantities, methods and means of measurement;- Functional principle of electrical appliances.Abilities: - To read circuits, determine the appointment of elements, analyze the modes of electrical circuits;- To make simple electrical circuits in cascade, parallel and mixed elements connection;- Perform simple calculations of electric circuits of direct and alternating current;- To calculate and design a simple circuit circuits in accordance with the technical specifications;- To choose electric devices intended to

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The name of cycles and disciplines Competencies deliveredperform electrical measurements.

Basics of standardization and metrology.Basic concepts and definitions in the field of standardization. Categories and types of standards. Metrology: basic concepts, organisational, scientific and methodological fundamentals. The legal framework to ensure the uniformity of measurements. A variety of measuring tasks. Classification of measurement according to kinds of measurements. Methods of measurement and control. Measurement and control tools. The use of computers in measuring tools. Requirements of modern metrology. The role of metrology to improve the quality of products, services and manufacturing. Methods and means of control of smooth cylindrical and tapered, threaded, key and splined, toothed and worm gears. Form and surfaces location deviation and their control. The role of technical regulation and standardization to ensure product quality. Assessing the level of product quality. Creation and development of international standards ISO 9000. The legal basis of technical regulation and standardization. The state supervision of standards and measuring instruments.

Knowledge:- Basic concepts, terms and definitions in the field of metrology, technical regulation and standardization, conformity assessment and quality control;- The types of standards used in professional activities;- Geometric parameters accuracy system;- Method of tolerances calculation and parts fitting;- Types, purpose and operation of measurement tools.Abilities:- To use information publications on standardization;- To apply the standards in practice;- To determine dimensions, deviations and tolerances of parts and their joints;- Identify clearance and tightness limits of joints;- To use technical measurement tools;- To use the pointers of standards and specifications; - To apply the necessary standards and other standardization documents for the task; - To use the list of tolerance, reduce quality indicators;- To control parameters when checking the quality of products at all stages of production;- To classify the types of defects and relate them to a specific group and the technological stage of production, which could occur.

Metal technology and welding.Manufacture fundamentals of ferrous and non-ferrous metals and alloys.

Knowledge:- A set of productions, combining iron and steel industry;

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The name of cycles and disciplines Competencies deliveredDevelopment areas of ferrous metallurgy. Production of powders, briquetting and sintering. Technology of thermal, chemical-thermal and thermo-mechanical metals and alloys processing. Alloy castability, castings’ designing and obtaining. Welding fundamentals. Welding methods classification and characterization. Machinery and equipment for gas welding. New methods of pressure welding without melting. Welding of cast iron, nonferrous metals and alloys, carbon and alloy steels. Hard-facing. Technology. Weld quality control. Fundamentals of metal cutting. Processing with turning, drilling, milling and other machines.

- The main directions of the production development of steel, nonferrous metals and alloys;- The main directions and prospects of development of fusion welding and pressure;- Atomic crystal structure of metals;- The composition and structure of metals and alloys, their classification;- Physical, chemical, mechanical and technological properties of metals and alloys;- Methods for determining the basic mechanical properties of metals;- Principles of construction of phase diagrams of alloys;- Types and purpose of structural and tool steels, including rebar;- Classification and labeling of steels, cast irons and non-ferrous alloys based on aluminum and copper;- The scope of the ferrous and non-ferrous metals and alloys;- The basis of production technology of steel, cast iron and non-ferrous metals;- Ways of reinforcing steel processing: thermal and chemical-thermal, surface hardening;- Basic ways to protect metals from corrosion;- Ways of metalworking with casting (sand and special forms), pressure, cutting;- Theoretical foundations of welding and metal cutting;- The sequence of welding;- Welding works in the construction and installation work;- Technology of arc welding, resistance welding;- Structure and working principle: welding machines for manual arc welding, spot welding machine.

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The name of cycles and disciplines Competencies deliveredAbilities:- To determine the hardness and impact toughness of metals;- To build cooling curves of iron-carbon alloys;- To determine the microstructure of carbon steel, alloy steel based on the results of microscopic analysis;- To read markings of steels, cast irons, non-ferrous metals and alloys;- To determine the kind of carbon steel and cast iron in their structure;- To appoint modes and perform basic operations of thermal treatment of carbon steels;- To read the conventions of welded joints in drawings;- To produce a weld quality control with one of physical methods.

Heat engineering.Theoretical basics of heat engineering. The thermodynamic processes of perfect gases. The basics of heat transfer. The basics of hydro- and aerodynamics. Thermal installations of special purpose. Furnace systems. Heat exchangers. The equipment for heat and humidity treatment. General information about heating devices. Firing heaters of mechanical repair departments of metallurgical plants.

Knowledge:- The basic rules of heat transfer processes, movement of liquids and gases in relation to the production units; - The basic rules of chemical and physico-chemical processes of mass transfer processes in relation to technological processes, units and equipment of metallurgy;- Major groups and classes of modern materials, their properties and the application of the principles of selection methods of computer graphics;- The methods of analysis processes and their impact on the quality of the products.Abilities:- To calculate and analyze internal and external processes of heat exchange in devices of various technological purpose, to choose rational thermal and heat regimes of metallurgical equipment work;

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The name of cycles and disciplines Competencies delivered- To apply the standard approaches to ensure health and safety and environmental friendliness;- To take the technological solutions that allow to use non-waste and resource-saving technologies in metallurgy;- To analyze, evaluate and select the metallurgical equipment of various technological purposes;- To analyze the technical and economic indicators of heating equipment;- To perform thermotechnical calculations of thermal installations;- To determine the cost of heat, coolant and fuel.

Records management in state language.Document classification and details. Role of documents and their significance. Nomenclature and records management procedures. Rules of document drafting. Paperwork in the Kazakh language: on staff, management activities, information and help. Record management using technical means.

Knowledge:- National standards and regulations for document management;- Record keeping system and the procedure for record keeping in the organisation;- Unified forms of primary records by the profile of professional activities;- Rules of preparation and execution of organisational and administrative documents;- Requirements for the preparation and execution of the main types of administrative documents;- General rules for the organisation of incoming, outgoing and internal documents;- The rules of the current document storage;- The procedure for the preparation of documentation for long term storage.Abilities:- Use regulations and methodological materials on record keeping and

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The name of cycles and disciplines Competencies deliveredarchiving, the standard of the unified system of organisational and administrative documents;- Draw up the details according to the layout;- Prepare and execute various types of organisational and administrative documents and copies thereof;- Fill in primary accounting documents by the profile of the professional activities;- Keep records of incoming and outgoing documents;- Prepare documentation for long term storage.

Basics of computer technology in the industry.Information systems for professional use. Databases as display system of business information. The system of standards on information technologies of business processing. Standards for electronic documents. Protecting of business information. Using the application software to perform the complex calculations. The technologies of creation and processing of textual information. The technologies of creation and processing of graphic and multimedia information.

Knowledge:- Trends in the development of information technologies;- Basics of building, the perspectives of local and global computer networks development, network technologies for information processing;- Ways of presenting and processing of technology, storage and transmission of information;- Classification of the PC software;- Numerical methods of solution and principles of mathematical simulation of applied problems;- Rules for using the hardware and software of the personal computer, systems and networks;- The purpose and possibilities of graphic and text editors, spreadsheets, and database management systems for the creation of technical documentation, applied in professional activity;- Methods of information protection.Abilities: - Use standard and application software

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The name of cycles and disciplines Competencies deliveredof a personal computer;- Apply modern methods of computer-aided design;- Create electronic documents;- Search for information on the Internet, use e-mail, modern information technologies.

Special disciplines

Theory and technology of foundry.Physical and chemical processes occurring in molding and core mixtures. Fillers of molding and core mixtures. Binders. Auxiliary materials classification and application. Physical and chemical processes taking place during the curing of sand-resin mixtures. Physical and chemical processes occurring during the curing of mixtures with inorganic binders. Basic theory of molding compounds properties. Mechanisms of casting defects and their prevention. Modern methods of molding sands and mixtures regeneration. Manual methods technology of molds and cores manufacture. Mechanized and automated methods for molding. Cores manufacturing technology. Design fundamentals of foundry equipment. Castings finishing technologies Environmental aspects of castings manufacturing technologies.

Knowledge:- common factors of selecting materials for molds and cores manufacturing;- main technological processes: preparation of mixtures, manufacture of molds and cores, casting, casting knockout, chipping and cleaning;- Methods of casting quality control;- Standards in the field of materials and casting technologies.Abilities:- Plan engineering processes for castings;- Identify and analyze basic physical and mechanical properties of molding and core mixtures;- Calculate basic elements and design a gating system to manufacture castings from various alloys;- Prepare documents on manufacturing pattern equipment and castings;- Launch castings manufacture, monitor their quality with minimum maintenance cost;- Analyze the prospects for the development of foundry technology and obtaining of the necessary new materials and equipment;- Choose effective criteria for technology development and equipment design to ensure casting meets the demands of today’s foundry;- Improve and streamline current processes on the basis of a systematic

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The name of cycles and disciplines Competencies deliveredapproach to the analysis of raw materials, existing processes and requirements to quality of products produced.

Foundry alloys and melting.Melts’ structure and properties. The impact of external influence on castings. Casting properties of alloys. Gettering and gas release in metals and alloys. Segregation. Metals and alloys segregation. Stress in castings. Modification and alloying. Foundry steel. Cast iron. High-strength cast iron with a spheroidal graphite and vermicular form. Non-ferrous casting alloys. Copper-based alloys. Aluminium alloys. Casting alloys based on magnesium, titanium, zinc and nickel.

Knowledge:- Modern concept of the structure and properties of metal alloys;- Patterns of alloy crystallization, and methods of their assessment;- Connection between alloy phase diagrams and the nature of crystallization, structure and casting properties of alloys;- Types of alloy heat treatment;- Equipment used and the physics and chemistry of melting processes;- Casting, physical, mechanical and performance properties of iron-carbon and non-ferrous metals and alloys, as well as their application.Abilities:- Use alloy phase diagrams to describe the nature of casting solidification, their structure and casting properties;- Determine by an experiment or calculation casting alloys characteristics;- Determine the mode of alloy heat treatment;- Choose effective melting equipment, modes and configurations for particular alloy types;- Analyze the causes of casting defects and to develop ways to eliminate them;- Calculate the required composition of the charging material;- Choose the alloy for a particular part with regard to its operating conditions.

Design and technological basis of the production of cores with hand molding.Technological bases for making cores with hand-molding methods. Formulas of core sand mixtures. Humidity control of materials and mixtures, strength in wet and

Knowledge:- Major technological methods used in hand-made cores;- Typical formulas of core sand mixtures used for manual molding of cores;- Methods of control of technological

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The name of cycles and disciplines Competencies deliveredin dry, gas permeability. The requirements for cores.

properties of core sand mixtures;- Working conditions of cores and basic requirements to them.Abilities: - Control the quality of core sand mixtures and condition of coreboxes;- Produce cores with detachable parts, frames and stalks;- Produce cores of ceramic mixture for casting of special steels;- Manufacture cores of fluid self-hardening and cold-hardening sands;- Complete cores for drying.

Economics, organisation and planning of production.Industry organisation in the system of market relations. Organisational bases of production. Organisation of flow-line and automated production. Auxiliary shops and services formation. Organisation of labor and payment. The tax system of the Republic of Kazakhstan in the context of market economy. New equipment development organisation and planning. Intrafactory planning organisation. Making up of a business plan. Fundamentals of accounting and analysis of industrial and economic activities within the organisations. Enterprise management. Innovations marketing. Innovations planning and management. Business structures formation procedure.

Knowledge:- State economic policy composition and structure;– Manufacturing organisations activity objectives and motives, their classification and structure;–Tasks, forms and spheres of business activity;– Organisation’s finances, financial recourses, profit structure and gross profit;– Labor payment organisation, organisation’s manufacturing staff composition and structure;– Organisation’s management mechanism;– Organisation’s economic activity planning;– Intrafactory economic relations;– Innovations organisation and planning;– Products quality and competitiveness management;– Organisation’s investment activity;– Organisation’s activity efficiency assessment: indicators, calculation methods, spheres of application;Abilities:– Analyze economic events and processes taking place within the foundry

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The name of cycles and disciplines Competencies deliveredand metallurgic industry organisations;– Make manufacturing and administrative decisions in order to achieve maximum results as for the activity of the organisation of foundry and metallurgic industry;– Carry out organisation’s activity planning;– Learn new forms of innovations and business activity.

Safety and health management.Health and safety management legal basis.Safety culture concept. Control and supervision service of occupational health and safety requirements in industry conditions organisation. General hygiene requirements for manufacturing facilities and workplaces. Technological equipment safety. Workers protection from radiation sources. Electrical safety fundamentals. Fire safety and fire protection. Hazardous and harmful industrial chemical factors. Safety and occupational health requirements, workplace policy in chemical laboratories. Safety insurance during repair and cleaning works. Legal and organisational issues relating to occupational health and safety principles.

Knowledge:– health and safety, risk theory fundamentals;– safety rules, industrial hygiene, fire safety and labor protection;– means and methods to improve safety, ecological compatibility and sustainability of technical means and technological processes;– safety requirements while working with main and auxiliary equipment;– operation of the staff health supporting and occupational safety system of different organisations;Abilities:– to measure and assess the parameters of working micro environment, the level of dust and gas pollution, noise and vibration, workplace illumination;– to control electromagnetic, ionizing and thermal radiation as well as the level of negative impacts for their compliance with regulatory requirements;– to analyze organisation’s activity in order to detect risks in the sphere of staff occupational health and safety;– to identify the hazards of production environment, assess the risk of their realization.

Equipment of foundry shops.General purpose equipment of foundry shops. Equipment for mechanization and

Knowledge:–Various machine types configuration, combined in technological groups and

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The name of cycles and disciplines Competencies deliveredautomation of charge-preparation and melting compartments. Mixture preparation equipment. Castings processing equipment. Equipment for special foundry methods. Hoisting apparatus of foundry shops. Transport facilities of foundry shops. Modern tendencies in the development of foundry equipment constructions.

are ensuring the implementation of main foundry manufacturing technology cycles;– Calculation methods of foundry equipment main assembly units;– Design principles of mechanized and automated complexes on the basis of manipulation software foundry equipment and robots;– Foundry machines maintenance and operation rules;– Modes and conditions of running of material-handling equipment;– Methods of equipment conditions diagnosing;Abilities:- to carry out technical and economic analysis of different options for foundry shops equipping with progressive foundry machines;– to solve engineering problems related to the development and improvement of new foundry equipment;– to perform the layout of equipment for different process stages according to the required castings production technology;- to analyze the construction of tracks and calculate their draft force;– to solve the tasks related to the foundry equipment operation, maintenance and its modernization.

Design and technological basis for the production of moulds for machine molding.The construction of coreboxes. Construction and operation of core machines. Mix formulations for machine production of cores in the manufacturing of foundry goods. Methods of control of technological properties of core mixtures. Manufacturing process and demands rose to the cores.

Knowledge:- The design and operation concept of coreboxes;- Construction and functional principle of core machines;- Mix formulations of core mixtures and other auxiliary materials used in the manufacture of cores and requirements to them;- Methods for determination of physical and mechanical properties and the quality

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The name of cycles and disciplines Competencies deliveredof core mixtures;- Order of the production of cores on machines and equipment of various types.Abilities:- Maintain, and adjust core machines; - Check the quality core mixtures; - Produce machine-made cores for coreboxes; - Control the quality of produced cores.

The systems of computer-aided design and simulation of foundry processes.Computer-aided design (CAD) fundamentals. The use of CAD software in foundry industry. Mold construction. CAD systems. CAD technology of casting. Computer modeling of casting processes. The system of computer-simulation «ProCast». The system of computer modeling "Polygon". Software and innovative technological processes to manufacture foundry equipment. Rapid prototyping technology.

Knowledge:- Modern systems of computer simulation of casting processes;- Casting processes simulation fundamentals in systems ProCast, Polygon, LVMflow etc.;- The possibilities of integrated systems design and engineering analysis of strength and structural dynamics;- Advanced rapid prototyping technology, designed to manufacture foundry and pattern equipment.Abilities:- Create CAD three-dimensional solid models;- Design a mold;- Develop the technological process using the simulation systems Polygon, ProCast, LVMflow etc- Apply the acquired knowledge in the design and development of foundry equipment and machinery.

Design of rigging.Development of model manufacture technology. Design and manufacture of models. Manufacture of wooden models. Manufacture of plastic polymers models. Metal casting patterns. Core boxes design. Foundry flask design. Press mold design and features for injection molding. Non-pressure mold design and its features. Mold design and features for centrifugal

Knowledge:- Modern materials and rigging for casting manufacture;- Calculating methods for basic rigging configurations;- Rigging distinctive design features for hand and machine molding;- Flask designs for different molding machines and automatic lines;- Mechanisms of press molds for

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The name of cycles and disciplines Competencies deliveredcasting injection molding, their design and parts

that make up the mechanisms.Abilities:- Analyze parts’ manufacturability for particular molding method;- Design rigging and its main elements;- Carry out drawings of various parts using standard software packages.

Automatic lines and systems.The methods of analysis, calculation and design of automatic lines and systems. Automatic foundry lines. Automated mixture-making complexes and systems of cores manufacturing. Automated systems for metal melting and casting. Automation of casting manufacturing finishing operations. Heat recovery of flue gas and gas treatment of foundry shops.

Knowledge:- Principles of construction and development of automated systems, automated lines and systems;- The main technical characteristics, layout and design features of automated lines and systems used in modern foundry production;- The organisation of automatic transfer lines and automated equipment for molding castings of special methods;- The methods of calculation and estimation of basic economic, technological, and exploitation parameters of automated lines and systems.Abilities:- Analyze the structure, composition and technological capabilities of automated-bath complexes, automated lines and systems;- Assess economic, technological and technical parameters of the automated lines and systems;- Calculate and design automated systems, automatic lines and systems for the implementation of the basic processes of foundry production.

Automation of foundry production.Automated control, monitoring and

Knowledge:– Operation principles of devices aimed

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The name of cycles and disciplines Competencies deliveredregulation of industrial processes. Automation systems. Automatic control systems (ACS). Systems of automatic control, regulation, remote control, automatic protection and block. Converters, actuators and regulators in automation systems. Control and measurement devices in foundry automated systems. Mixture preparation processes automation. Molds and cores manufacturing processes automation. Melting and casting automation. Automation of castings shake-out and cleaning processes. Special foundry methods automation. Methods and tools for environmental conditions control. Automated lines and systems. Methods of analysis, calculation and design of automated lines and systems. Automated molding lines. Automated mixture preparation complexes and cores manufacturing systems. Automated complexes for metal melting and castings manufacturing completion operations performance.

at automated control, automated protection and blocking remote control regulation, converters, control and measurement devices in foundry processes and equipment automation;– Requirements to be met by modern automated production;– Rinciples of automated complexes, lines and systems construction and design;– Basic specifications, layout and design characteristics of automated lines and systems used in modern foundry manufacturing;– Vethods of calculation and evaluation of basic economic, technological and operational parameters of automated lines and systems.Abilities:– To develop functional block diagrams featuring foundry processes and equipment automation;– To analyze the structure, composition and technological capabilities of automated complexes, automated lines and systems;– To assess economic, technological and technical parameters of automated lines and systems;– To calculate and design automated complexes, automated lines and systems aimed at the implementation of basic technological processes of foundry production.

Industrial training and professional practiceIndustrial training

Fitting and mechanical training practice.Mastering of different types of fitter works. Auxiliary instruments, control and measuring instruments selection and use. Equipment maintenance, repair, testing

Abilities:– To perform the fitter processing of parts;– To use the system of tolerances and fits, quality class system and roughness parameters while performing the fitting

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The name of cycles and disciplines Competencies deliveredand acceptance. Fitting and assembly work. Compliance with health and safety requirements. Compliance with the order principles and culture of work completion, careful equipment operation and materials handling.

of the parts;– To choose and apply the fitting and measuring tools, general-purpose and special instruments while performing of fitting;– To use equipment and facilities effectively;– To eliminate the simplest of equipment malfunctions;– To consider mechanical and other properties of processed materials during the work;– To read technical documentation, follow the technical conditions during the work performance;– To organize the workplace during the work performance efficiently;Skills:– To perform works using main types of process equipment;– To comply with health and safety requirements while completing hand and machine tool operations.

Professional practiceIndustrial training on the acquisition of worker profession “Core maker of hand molding”.Introduction to the structure of a foundry shop, modern foundry production equipment. Students’ preparation for practical work as laborers. Coreboxes preparation. Manufacture of cores of large and small sizes, of simple and medium complexity. Manufacture of cores of simple and medium complexity from ceramic mixture. Cores assembly and gluing. Deburring.

Abilities:– To control the quality of core sands and conditions of coreboxes;– To produce cores according to coreboxes with loose parts and frames;– To produce cores from ceramic mixturefor castings from special alloys;– To produce cores from liquid self-hardening and cold hardening mixtures;– To carry out molds packing, cleaning, gluing, and painting of cores;– to assemble coreboxes, stacking of frames, laying of wicks and cutting of channels during the manufacture of complex cores;– To carry out packaging and packing/laying of cores on drying plates.Skills:

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The name of cycles and disciplines Competencies delivered– To analyze the technology of hand manufacturing of foundry cores and of practical application of materials;– To carry out the process of foundry cores hand manufacturing.

Industrial training on the acquisition of worker profession “Core maker of machine molding”.Students’ preparation for practical work as laborers. Service and corrective adjustment of core-making machines and automatic machines. Preparation of coreboxes. Quality control of core sands. Production of cores of simple and medium complexity according to the coreboxes using core-making machines and automatic machines. Finishing, painting, and laying of cores for drying.

Abilities:– To control the quality of core sands and conditions of coreboxes;– To perform maintenance and adjustment/setup of core-making machines and automatic machines;– To carry out the production of cores according to the coreboxes;– To control the quality of manufactured cores;– To carry out the assembly and gluing of cores.Skills:– To analyze the technology of machine manufacturing of foundry cores and of practical application of materials;– To carry out the process of foundry cores machine manufacturing.

Industrial practice for acquisition of the worker profession “Mechanic-foundryman on machines and automatic lines”.Mastering of the techniques of technological equipment maintenance. Preparation of students for practical work as workers. Running of process of preparation, regeneration and drying of molding materials and sands, as well as molding. Production of foundry molds and cores. Implementation of interaction of works at the sites. Running of the operating log.

Abilities:– To identify and rectify faults in functioning of equipment being in service;– To carry out the setup and control/regulating of machines and automatic lines;– To run the process of molding and core sands preparation;– To control the quality of molding sands and cores;– To produce foundry molds;– To produce cores on machines and automatic lines.Skills:– To run machines and automatic lines designed for castings production;– To run the process of molding and core sands preparation, of producing molds

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The name of cycles and disciplines Competencies deliveredand cores.

Industrial practice in designing and manufacturing of tooling.Mastering of the technology of wooden foundry and pattern equipment production using numerically controlled machines. Mastering of the technology of foundry and pattern equipment production made from polymeric materials using numerically controlled machines. Mastering of the technology of foundry and pattern equipment production from liquid two-component polymeric materials.

Abilities:– To implement the main steps of foundry and pattern equipment manufacturing on numerically controlled machines;– To manufacture wooden foundry and pattern equipment;– To manufacture foundry and pattern equipment made from polymeric materials;– To manufacture foundry and pattern equipment from liquid two-component polymeric materials.Skills:– To develop the design/structure of coreboxes and pattern equipment (tooling);– Tto create NC programs for production of foundry and pattern equipment, taking into account the principles and the sequence of processing of wood materials and polymeric materials on numerically controlled machines;– To carry out the preparation of two-component liquid polymer materials and manufacturing of foundry and pattern equipment from them.

Technological practice.Practicing the theoretical and practical knowledge acquired by students while studying general and special disciplines. Participation in the work procedures being completed by the foundry shop workers. Mastering of the principles and skills of foundry shop departments management. The acquisition of practical skills concerning the casting production technology development as well as the necessary technical documentation development. Equipment maintenance and repair documents completion. The

Abilities:– To use the equipment and facilities efficiently;– To maintain the established order of foundry engineering technological processes;– To rectify the simplest foundry shop equipment faults/malfunction;– To plan the working day schedule at the working site;– To execute orders for work performance;– To fulfill duties at the workplace;– To organize planned preventive

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The name of cycles and disciplines Competencies deliveredproduction of work performance order. Briefing at the workplace. Planning of the day schedule and the analysis of the site work performance. Types of payment analysis. Planned preventive maintenance organisation.

maintenance;– To make photos of the working day; to process these photos.Skills:– To exercise control over work performance following the current provisions and rules concerning occupational safety, industrial hygiene and fire protection;– To perform work using the main types of technological equipment of a foundry shop independently;–To hand out the tasks to those who are in charge;– To exercise briefings at the workplace;– To maintain relations with related engineering and technical personnel;– To supervise the staff performing work at the site.

Pre-diploma practice.Practicing the principles of production organisation and management, analysis of foundry shop and its sites economic indicators as well as measures aimed at improving the efficiency of their functioning. The familiarization with/mastering of software systems used for technological equipment design, castings engineering, gating systems improvement, calculation, analysis, optimization of foundry manufacturing facilities operation. Collection of all necessary materials and documents in order to make a diploma project (to write a diploma paper).

Abilities:– To read technical and technological documentation;– To meet the requirements specified in technological instructions;– To make the cost of production;– To analyze the economic indicators of foundry shop and its sites operation.Skills:– To follow the demands of health and safety at the workplace;– To complete the documents according to the specified requirements.

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Educational programs on the disciplines

BASICS OF ENGINEERING GRAPHICSThe purpose of the study of the academic discipline is to develop

students' abilities to interpret and produce drawings and schemes in accordance with standards of the Unified System of Design Documentation (ESKD).

SUMMARY OF DISCIPLINE

Section, topic

Number of hours

total

Including those for practical

work1 2 3

Introduction 1Section 1. Graphic presentation of drawings 9 61.1. Drawing lines. Inscriptions. Scales. Dimensioning 5 41.2. Geometric constructions 4 2Section 2. Descriptive geometry and projection drawing fundamentals

36 24

2.1. Point. Straight line. Plane 4 42.2. Projecting of geometrical bodies.Axonometry

6 4

2.3. Intersection of geometric bodies with projecting planes 4 22.4. Mutual intersection of geometric body surfaces 6 22.5. Projection drawing 4 42.6. Views, cuts, sections 8 6Test 1 22.7. The drawing as a ESKD document 2 2

Total 46 30Section 3. Machine drawing 36 163.1. Views and symbols of threads 4 23.2. Drafts and drawings of parts 8 23.3. General arrangement drawings. Assembly drawings. Detachable and permanent joints

16 8

3.4. Drawings interpreting. Detailing 8 4Section 4. Specialized drawings and schemes 18 24.1. Forms and types of diagrams. General rules for producing diagrams

6

4.2. Block diagrams. Functional diagrams 6Test 2 24.3. Electrical schematic diagrams 4 2

Total 54 18Overall 100 48

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CONTENTS OF THE DISCIPLINEContents of the topic Results Assessment criteria

IntroductionGoals and objectives of the discipline Engineering Graphics Fundamentals, its relationship with other academic disciplines, the significance in the training.Brief information on the development of engineering graphics and standardization. The ESKD standards: the scope of their application, the role when producing drawings. Drawing instruments and supplies.

The student should express a general judgment about the goals and objectives of the discipline Engineering Graphics Fundamentals, its relationship with other academic disciplines.

The student should express a general judgment about the goals and objectives of the discipline, its significance in the training system, intent and application of basic drawing instruments, on the application of ESKD standards and their role in producing drawings.

Section 1. Graphical presentation of drawingsTopic 1.1. Drawing lines. Inscriptions. Scale. Dimensioning

Types of drawings. Formats. Drawing lines. Drawing font. Title block. Instruments. Technique for using drawing instruments. Scale. General rules for dimensioning drawings.

The student should know the main lines, forms, title blocks, drawing scales.The student should be able to describe the rules for dimensioning drawings.

The student should describe the types of drawings, formats, and title block. The student should articulate the intent of drawing lines and scales.

Practical work 1Producing drawing lines. Writing words, digits, sentences with the drawing font. Dimensioning.

The student should produce drawing lines. Writing words, digits, sentences with the drawing font.

The student should produce drawing lines, letterings with the drawing font, and dimension drawings in accordance with the ESKD standards.

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Contents of the topic Results Assessment criteriaTopic 1.2. Geometric constructions

Geometric constructions: division of segments, circles on equal parts. Connection of two straight lines with an arc of a given radius, a straight line and arc, two arcs. Methods of drawing technical detail geometrics with geometric constructions, building a connection.

Creation of geometric constructions of different complexity.

The student should explain basic geometric constructions, formulate the general principles of building connections, and articulate the essence of the concept of "a point of connection."

Practical work 2Producing basic geometric constructions. Building various line connections.Producing technical detail geometrics, dimensioning in accordance with the GOST and ESKD requirements. Dimensioning drawings and limit deviations.

Production of technical detail geometrics. Dimensioning in accordance with the GOST and ESKD requirements.

The student should produce basic geometrical constructions, and build a connection of two straight lines, external and internal connections of two arcs, internal and external connections of a straight line and an arc with arcs of a given radius, etc.The student should build the geometrics of the technical detail along with producing the necessary geometric constructions and connections on the drawing, and dimension in accordance with the requirements of the ESKD standards.

Section 2. Descriptive geometry and projection drawing fundamentalsTopic 2.1. Point. Straight line. Plane

Types of projection. Projection planes. Coordinate axes. Projecting a point and a line segment on two or three

The student should produce projection and connection between the notions of a point, line and planes.

The student should explain the projection of geometric bodies, describe how to specify the plane on the drawing, methods

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Contents of the topic Results Assessment criteriaprojection planes. Straight lines in general and particular position. Complex drawings. Mutual arrangement of straight lines.Specification of the plane on the drawing. Projecting a plane on two and three projection planes. Plane of reference. Projective plane.

of building points and straight lines of the projection which belong to the plane, plane mutual arrangement, and cover the question of points and lines attaching to planes and their mutual arrangement.

Practical work 3Building the projection of points and straight lines belonging to the plane. Geometric relationship.

Building of the projection of points and straight lines belonging to the plane. Building of geometric relationship.

The student should build point projections, a segment of the straight line, and project a plane on two and three projection planes.

Topic 2.2. Projection of geometric bodies. AxonometryProjection of geometric bodies on two and three projection planes with a detailed analysis of the elements of geometric bodies. Building projections of the points belonging to the surface of geometric bodies.Axonometry types. Axonometric axis. Distortion factors. Rules for building axonometric views of points, straight lines, plane figures, and geometric bodies. Building a circle in an isometric projection.

The student should build the projection of geometric bodies and axonometry projections in the drawing.

The student should explain the building process of projections of basic geometric bodies and projections of points belonging to the surface of the geometric bodies, describe axonometry types, axonometric axis distortion factors, and set out rules for building axonometric views of points, straight lines, plane figures, and geometric bodies.

Practical work 4Producing complex drawings of geometric bodies with projections of

Projecting of points belonging to the surface of the geometric bodies and

The student should build complex drawings of basic geometric bodies in three

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Contents of the topic Results Assessment criteriapoints belonging to the surface of the geometric bodies. Building axonometric views of geometric bodies.

their axonometry. projections, projections of the points belonging to the surface of the geometric bodies, axonometric views of geometric bodies.

Topic 2.3. Intersection of geometric bodies with projecting planesSection. The intersection of geometric bodies with projecting planes. Building developed views.

The student should build intersections of geometric bodies with projecting planes.

The student should formulate the definition of "section" term, characterize the lines of intersection of geometric bodies with projecting planes, and describe developed drawings of geometrical body surfaces, set out the procedure for building intersection lines of geometric bodies with planes, developed drawings, and axonometric views of truncated geometric bodies.

Practical work 5Building an axonometric view of a truncated geometric body.Building complex drawings of truncated geometric bodies.

The student should build an axonometric view and complex drawings of truncated geometric bodies.

The student should build the drawing of an axonometric view and developed views of a geometric body truncated projecting plane.The student should build a complex drawing of a truncated geometric body.

Topic 2.4. Mutual intersection of geometric body surfacesThe line of intersection of geometric bodies. Building the line of mutual intersection of surfaces. The intersection of polyhedra. Intersection of bodies of revolution. Various cases of mutual intersection of geometric

The student should build the lines of mutual intersection of surfaces. of geometric bodies.

The student should set out the rules for building the line of mutual intersection of surfaces of various geometric bodies.

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Contents of the topic Results Assessment criteriabodies. Auxiliary section plane method.

Practical work 6Building the line of mutual intersection of the geometric body surfaces and axonometric views of intersecting surfaces of geometrical bodies.Building complex drawings of intersecting geometric bodies using the auxiliary section plane method.

The student should build axonometric views and complex drawings of intersecting geometric bodies using the auxiliary section plane method.

The student should build a line of mutual intersection of the surfaces of the geometric bodies and axonometric views of the intersecting surfaces of geometric bodies.The student should build complex drawings of intersecting geometric bodies using the auxiliary section plane method.

Topic 2.5. Projection drawingThe form of the model as a combination of simple geometric bodies. Building the third projection of the model based on two projection available and its axonometric view.

The student should build the projection of a third model based on two projection available and its axonometric view.

The student should characterize the shape of the model as a combination of simple geometric bodies.The student should build the projection of a third model based on two projection available and its axonometric view.

Practical work 7Building complex drawings and axonometric views of simple models.

The student should build complex drawings and axonometric views of simple models.

The student should build complex drawings and axonometric views of simple models.

Topic 2.6. Views, cuts, sectionsViews. Intent of the views. Layout of the main views in the drawing. Additional views, their layout and identification. Fragmentary views, their use, layout, identification, and design.

The student should describe and apply cuts and sections in the drawings.

The student should describe views, cuts, and sections, explain their function, layout and identification in drawings.

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Contents of the topic Results Assessment criteriaSimple cuts: their intent and layout in the drawing. Connection of the cut part with a part of the respective view. Fragmentary and complex cuts (step, broken). Application, layout and identification in the drawings. Sections: detail section and broken section. The application, layout, and identification in the drawings.

Practical work 8Producing complex drawings of simple models using simple and complex cuts and sections.Producing complex drawings of educational models of average complexity using simple cuts, building an axonometric view with ¼ notch.

The student should produce complex drawings of simple models using simple and complex cuts and sections, building an axonometric view with ¼ notch.

The student should build and interpret complex drawings of simple models cuts and sections.The student should build drawings of average complexity using simple cuts, an axonometric view of the model with ¼ notch.

Test 1Topic 2.7. The drawing as a ESKD document

Types of products and design documents. Name of design documents depending on the purpose. Title blocks on design documents.

The student should describe the drawings as the document of ESKD.

The student should distinguish types of products and design documents.

Practical work 9Producing title boxes on design documents.

The student should produce title boxes on design documents.

The student should produce title boxes on design documents.

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Contents of the topic Results Assessment criteriaSection 3. Machine drawing

Topic 3.1. Views and symbols of threadsThread: purpose and formation. Types of threads. Thread elevations. Conventional representation of external and internal threads.Views and symbols of standard threaded fasteners.

The student should describe the profiles, types and symbols of threads.

The student should explain the purpose and formation of the thread, describe the types and profiles of threads, and set out rules for conventional representation and indication of threads. The student should identify views of standard threaded fasteners and their symbols in drawings.

Practical work 10Building views and the symbols of threaded parts and standard threaded fasteners in the drawing.

The student should build views and symbols of threaded parts in the drawing.

The student should build views of threaded parts and standard threaded fasteners and indicate them in accordance with ESKD standards.

Topic 3.2. Drafts and drawings of partsThe form of parts and their elements. Purpose and content of the draft and design drawings. The sequence of drawing up the draft of parts from nature. The procedure of producing the design drawing of parts based on their drafts. Dimensioning. Measuring tools. Representation of materials in drawings.

The student should describe the forms of parts and their elements. The student should characterize their purpose and content of the draft and design drawings..

The student should explain the purpose and content of the draft and design drawing of parts, set out the sequence of drawing up the draft of parts from nature, the procedure of producing the design drawing of parts based on their drafts, part measurement rules, and describe the measuring tool, dimensioning, material symbols in the drawings.

Practical work 11Producing a draft of threaded parts using sections. Producing a draft of parts using cuts.

The student should produce a draft of parts using cuts.

The student should perform the measurement of parts, produce a draft of threaded parts using sections and cuts,

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Contents of the topic Results Assessment criteriaperform dimensioning, and indicate the brand of the material.

Topic 3.3. General arrangement drawings. Assembly drawings. Detachable and permanent jointsGeneral arrangement drawings: purpose and content. Assembly drawings: purpose and content. Conventions and simplification in assembly drawings. The sequence of producing assembly drawings based on part drafts. Specification. Types of joints. Detachable joints: threaded, keyed, serrated, pinning, their purpose and representation in drawings. Permanent joints: soldered, glued, welded, and riveted, their representation and symbols in drawings. The types of joints. Separable joints: threaded, key, serrated, doweling, their function and the image at drawings. Permanent joints: braze, glued, welded, and riveted, their image and drawing symbols.

The student should describe the general arrangement and assembly drawings. The student should draw up specifications. Determination of types of connections. Formulation, application and drawing of detach-able and permanent joints.

The student should set out the purpose and content of general arrangement drawings and assembly drawings, explain the conventions and simplification in assembly drawings, communicate the sequence of producing assembly drawings based on part drafts, describe the types of joints, their representation and symbols in drawings, and set out rules for filling in specifications. Describes the types of joints, their image and drawing symbols.Interprets the rules of assembly drawings design elements, a simplified image of the thread in a joint, the drawings of bolted-type, screw and key connection of details with the use of simplifications.

Practical work 12Producing drawings of threaded joints. Producing drafts of assembly unit parts. Producing assembly drawings based on drafts of parts. Drawing up

The student should produce assembly drawings based on drafts of parts. The student should draw up specifications.

The student should produce drawings of threaded joints, drafts of assembly unit parts, assembly drawings based on drafts of parts, draw up the specification.

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Contents of the topic Results Assessment criteriaspecifications.

Practical work 13Producing assembly drawings of joints. The student should produce assembly

drawings of joints.The student should produce assembly drawings of joints.

Topic 3.4. Drawings interpreting. DetailingInterpreting assembly drawings: analysis of purpose and operation of assembly units, the number of original and standard parts included in the assembly unit, the order of assembly and disassembly, coupling size.Detailing: producing design drawings of parts based on assembly drawings.

Interpreting assembly drawings: analysis of purpose and operation of assembly units, the number of original and standard parts included in the assembly unit, the order of assembly and disassembly, coupling size.Detailing: producing design drawings of parts based on assembly drawings.

The student should interpret general arrangement drawings (assembly drawings) using the algorithm, communicate the sequence of development of the design drawing of the part based on the assembly drawing.

Practical work 14Producing design drawing of a part. Producing design drawings of parts based on assembly drawings of a product.

Producing design drawings of parts based on assembly drawings of a product.

The student should produce a design drawing of a part. Produce design drawings of parts based on assembly drawings of a product.

Section 4. Specialized drawings and schemesTopic 4.1. Forms and types of diagrams. General rules for producing diagrams

Forms and types of diagrams. General rules for producing circuit diagrams. Graphical symbols of elements (GS) used in circuit diagrams. Reference numerals. Drawing up a list of elements.

Description of types of diagrams. Characteristics of general rules for producing circuit diagrams.

The student should describe forms and types of diagrams, set out the general rules for producing circuit diagrams, and describe graphical symbols of elements on circuit diagrams.The student should stamp graphical symbols of elements on circuit diagrams,

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Contents of the topic Results Assessment criteriaand draw up a list of elements.

Topic 4.2. Block diagrams. Functional diagramsRules for producing block circuit diagrams, function circuits diagrams, filling in their title blocks.Producing block circuit diagrams.

Knowledge of rules for producing block circuit diagrams, function circuits diagrams, filling in their title blocks.

The student should set out the rules for producing block circuit diagrams, function circuit diagrams, and fill in their title blocks.The student should produce block circuit diagrams, fill in the title block, and draw up a list of elements.

Test 2Topic 4.3. Electrical schematic diagrams

Rules for producing electrical schematic diagrams, filling in the title block of electrical schematic diagrams, and drawing up a list of elements to it.

Knowledge of rules for producing electrical schematic diagrams, filling in the title block of electrical schematic diagrams, and drawing up a list of elements to it.

The student should set out the rules for producing electrical schematic diagrams, filling in the title block of electrical schematic diagrams, and drawing up a list of elements to it.

Practical work 15Producing electrical schematic diagrams.

The student should build electrical schematic diagrams.

The student should produce electrical schematic diagrams, fill in the title block of electrical schematic diagrams, and draw up a list of elements.

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GuidelinesTo implement the syllabus on the academic discipline Fundamentals

of Engineering Graphics, we recommend the following teaching forms: lectures, seminars, and laboratory work.

Given the nature and complexity of the educational material content, we recommend the following teaching methods: lectures, conversations, discussions, cases, the analysis of work situations, role-playing and simulation games, brainstorming, presentation of material, work in micro groups and others.

Forms of cognitive activities are advisory in nature. Number of hours to study sections can be changed while keeping the minimum content.

In presenting the program educational material it is required to observe the unity of terminology and symbols of technical values and dimensions in accordance with current regulatory and technical legal acts and the International System of Units (SI), and be guided by the ESKD standards.

To ensure an adequate level of training when studying the academic discipline, it is recommended to use the technical, electronic learning tools, etc. The syllabus contains an indicative list of classroom equipment, technical and demonstration facilities required to ensure the educational process.

The main form of educational process of the academic discipline Fundamentals of Engineering Drawing is practicals. The content of practicals includes the formation of initial skills of interpreting and producing drawings and diagrams. Graphic works are drawn on the drawing paper of standard paper sizes (A4 or A3), and drafts are drawn up on checker paper. During assignments, students also acquire the skills to use the drawing tools and supplies.

Academic discipline Fundamentals of Engineering Drawing is studied in close connection with the academic disciplines of the general professional cycle such as Basics of Engineering Mechanics, Electrical Engineering with the Basics of Electronics, Fundamentals of Standardization and Metrology.

The control of this academic discipline provides for interim assessment, basic forms of which are the following: quizzes, passes, and tests.

The implementation of this syllabus provides for carrying out of the following:

- Quizzes - 2;- Passes- 1.Educational organizations must develop competence-oriented tasks

in the test form and include them in the syllabus.Tests should be presented by sections and topics and have three basic

levels of complexity (minimum, medium and hard).Studying the academic discipline, the student should

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know the following:- Drawing formats, types of lines, their purpose, drawing fonts,

geometric constructions, scale;- Projection methods, axonometry types, building views, cuts,

sections;- Symbols used in electrical schematic diagrams, functional circuit

diagrams, kinematic, pneumatic, hydraulic and other diagrams;- Rules for the producing, presentation and Drawings interpreting,

diagrams, design and technological documentation.be able to:

- Produce drawings, diagrams, and drafts;- Interpret and present drawings;- Express the technical idea using the drafts, drawings, and technical

drawing.

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BASICS OF TECHNICAL MECHANICS

The purpose of the study of the academic discipline is the development of technical thinking of students, skills of working with regulations and reference books.


Section, topic

Number of hours

total

Includingthose

of laboratory work

those of

practical

workIntroduction 1Section 1. Engineering Mechanics 37 2 141.1. Basic concepts and axioms of statics 31.2. The flat system of converging forces 6 41.3. The plane arbitrarily spaced force system 4 21.4. Spatial force system 6 41.5. The center of parallel forces and center of gravity 3 2Test 1 11.6. Basic concepts of kinematics. Kinematics of the point. Simple rigid body motions

6 2

1.7. Basic concepts and axioms of dynamics. The motion of a material point

4 2

1.8. Work and power 4Section 2. Strength of materials 46 2 242.1. Basic provisions 22.2. Tension and compression 10 62.3. Shear and bearing stress 10 2 42.4. Torsion. Geometric characteristics of flat sections 10 82.5. Bending. Curved bending 10 62.6. Stability of centrally compressed bars 3Test 2 1Section 3. Machine parts 183.1. Basic provisions 43.2. Types of gears 83.3. Shafts and axles. Bearings. Sockets 23.4. Joints of machine parts 4

Total 102 4 38

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IntroductionGoals and objectives of the academic discipline Fundamentals of Engineering Mechanics, its relationship with other disciplines of the special cycle. The role and importance of Engineering Mechanics in construction.The main parts of the theoretical mechanics: statics, kinematics, and dynamics. Strength of materials. Machine parts.

Expression of a general judgment about the goals and objections of the academic discipline Basics of Engineering Mechanics.

The student should name the goals and objectives of the discipline, and express a general judgment about the role and importance of Engineering Mechanics in construction.The student name sections of the academic discipline Basics of Engineering Mechanics.

Section 1. Engineering MechanicsTopic 1.1. Basic concepts and axioms of statics

Basic concepts of statics: mass point, rigid body, force (force as a vector, units of measurement). Systems of forces and their classification. Equivalent and balanced system of forces. Resultant force.Axioms of statics: the first axiom (law of inertia), the second axiom (a condition of equilibrium between two forces), the third axiom (principle of addition and exclusion of balanced forces), the fourth

Knowledge of the basic concepts of statics: mass point, rigid body, force (force as a vector, units of measurement). Description of systems of forces and their classification.

The student should name basic concepts and axioms of statics, and explain the determination of the reaction direction of the main types of relationships.

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Contents of the topic Results Assessment criteriaaxiom (law of parallelogram), the fifth axiom (the law of action and reaction).Relationships and their classification; response relationships and determination of their direction.

Topic 1.2. The flat system of converging forcesThe system of converging forces. Methods of adding two forces. Expansion of the force into two components. Power polygon. The force projection on the axle, the sign convention. The projection of the forces on the two mutually orthogonal axes. Analytical determination of the resultant. The condition of equilibrium of the plane system of converging forces in the geometric and analytic form. The equilibrium equations. Method of calculation of typical tasks using the equilibrium equations. Rational choice of coordinate axes.The rotating action of a force couple on the body. The shoulder and the moment of the force couple, the sign convention. Equivalent pairs.

Description and characteristics of the convergent force system.

The student should reveal the essence of the term diagram of forces, force projection on the axle, communicate geometric and analytical conditions of equilibrium of the convergent force system, and explain the methodology for calculating the typical tasks using the equilibrium equations.The student should reveal the essence of the terms force couple, moment of a couple, moment of force about a point, and explain the properties of a force couple, and couple equilibrium condition.

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Contents of the topic Results Assessment criteriaProperties of the force couple. Addition of couples. The condition of the couple equilibrium. The shoulder and the moment of force about a point, the sign convention.

Practical work 1Determination of efforts in the rods of the bracket.

Determination of efforts in the rods of the bracket.

The student should determine efforts in the rods of the bracket by different ways.

Practical work 2Determination of a force couple, a moment of force about a point.

Determination of force couples, a moment of force about a point.

The student should determine force couples, a moment of force about a point.

Topic 1.3. The plane arbitrarily spaced force systemBringing the power and the plane system of forces arbitrarily spaced in the center, the resultant vector and the main moment of the plane system of arbitrarily spaced forces. Varignon theorem of the resultant moment. The equilibrium of the plane force system; analytical equilibrium condition. The main types of beam system supports: hinged movable support, hinged immovable support, rigid fixing, their reactions. Classification of loads: concentrated force, concentrated force couples

Determination of the essence of the notion and description of the plane system of forces arbitrarily spaced in the center.

The student should reveal the essence of the term "the resultant vector" and "the main moment," explain the equilibrium equations, the direction of reactions of beam system supports and the classification of loads.

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Contents of the topic Results Assessment criteria(moments), distributed loads, and their intensity.

Practical work 3The solution of equilibrium equations in the plane arbitrarily spaced force system of (three types).The solution of the equilibrium equations to determine the support reactions of plane-loaded beams statically defined.

The solution of equilibrium equations in the plane arbitrarily spaced force system of (three types).The solution of the equilibrium equations to determine the support reactions of plane-loaded beams statically defined.

The student should calculate the beam using the equilibrium equations.The student should calculate the support reactions of plane-loaded beams statically determined.

Topic 1.4. Spatial force systemThe spatial converging force system. Addition and the resultant of the spatial converging force system. The force projection on the axle not lying with it in the same plane. The equilibrium of the spatial converging force system. The moment of force about the axis, its symbol and the equality-to-zero condition.The spatial arbitrarily spaced forces system, its equilibrium.

Description of the spatial converging force system. Projecting of force on the axle not lying with it in the same plane.

The student should characterize the spatial force system.The student should explain equilibrium equations of the spatial arbitrarily spaced force system, and define the moment of force relatively to the axis.

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Contents of the topic Results Assessment criteriaPractical work 4

The solution of equations in the equilibrium of the spatial converging force system.

The solution of equations in the equilibrium of the spatial converging force system.

The student should calculate equations of the equilibrium of the spatial converging force system, and identify the moment of force about the axis.

Practical work 5

The solution of the equilibrium equations to determine the support reactions of spatially loaded shafts.

The solution of the equilibrium equations to determine the support reactions of spatially loaded shafts.

The student should solve equations the equilibrium equations to determine the support reactions of spatially loaded shafts.

Topic 1.5. The center of parallel forces and center of gravityThe addition of parallel forces. The resultant, the center of parallel forces, its properties and formulas for determining the coordinates of the center of parallel forces. Gravity as a resultant of parallel forces. The center of gravity of the body. The coordinates of the center of gravity of a thin uniform plate. Static moment of area of a plane figure with respect to the axis. Formulas for determining the coordinates of the center of gravity of complex plane figures. The center of gravity of the sections having an axis of symmetry. The center of gravity of

Formulation of notions, description of the methodology for determining the coordinates of the center of gravity composed of simple geometric figures and standard structural section views.

The student should reveal the essence of the term "center of parallel forces", "gravity", "center of gravity", and "static moment". The student should explain the methodology for determining the coordinates of the center of gravity composed of simple geometric figures and standard structural section views.

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Contents of the topic Results Assessment criteriasimple geometric figures: rectangle, triangle, semicircle. Determination of center of gravity coordinates of thin plates (sections) composed of simple geometric figures and standard structural section views.

Laboratory work 1Determination of the center of gravity of plane figures of complex sections.

Determination of the center of gravity of plane figures of complex sections.

The student should determine the position of the center of gravity of plane figures of complex sections.

Test 1Topic 1.6. Basic concepts of kinematics. Kinematics of the point. Simple rigid body motions

Definition of kinematics as the science of mechanical motion; quiescence and motion relativity. Basic concepts of kinematics: a reference frame, trajectory, path, distance, time, rate, acceleration.Methods of specifying the motion of the point: geometric (natural) and coordinate. The average rate and rate at a given time. Full, normal and tangential acceleration. Types of the point motion depending on the acceleration (rectilinear and curvilinear, steady and variable motion of the point). Uniformly variable motion of the point.

Knowledge of the basic concepts of kinematics. Formulation of the basic concepts of the simple point motion.

The student should express general judgments about kinematics as the science of the mechanical movement, about the relativity of quiescence and motion. The student should name basic concepts of kinematics.The student should explain the difference between the average velocity and the velocity at a given time, and describe the types of acceleration, the types of the point motion depending on acceleration.The student should explain the essence of translational and rotational motion of a rigid body, the linear velocity and acceleration of points of a rotating body. The student should explain the expression of the linear velocity and acceleration of points of a rotating body through

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Contents of the topic Results Assessment criteriaTranslational motion. Determination of distance covered, speed and acceleration of points.The rotational motion of a rigid body about a fixed axis. The angular displacement, angular velocity (the average velocity and velocity in a given time), the frequency of rotation. Types of rotational motion of a rigid body: steady and non-steady (uniformly variable). The equations of rotation, main and auxiliary formula.Linear velocity and acceleration of points of a rotating body. The expression of the rate, normal, tangential and full acceleration of points of the rotating body through its angular velocity and angular acceleration.

its angular velocity and acceleration.

Practical work 6Tracing of rigid body trajectory on various surfaces.

Tracing of rigid body trajectory on various surfaces.

The student should produce tracings of rigid body trajectory on various surfaces.

Topic 1.7. Basic concepts and axioms of dynamics. The motion of a material pointBasic concepts: mass, material point, force (constant and variable). The axioms of dynamics: the first

Knowledge of the basic concepts and axioms of dynamics.

The student should reveal the essence of the fundamental concepts of dynamics, communicate axioms of dynamics, and

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Contents of the topic Results Assessment criteriaaxiom (law of inertia), the second axiom (fundamental law of dynamics of a material point), the third axiom (law of superposition), the fourth axiom (law of action and reaction). The main problem of dynamics: direct and inverse.Free and non-free material points. The force of inertia at rectilinear and curvilinear motion of a material point.

Description of the point motion.

formulate direct and inverse problems of dynamics.The student should define the term of the free and non-free point, and the force of inertia, describe the inertial forces at rectilinear and curvilinear motion of a point.

Practical work 7An algorithm for solving problems in the balance. D'Alembert's principle. Kinetostatics method.

Solving the problems in the balance using various methods.

The student should explain the algorithm for solving the problems in the balance, determine D'Alembert’s principle, and solve problems according to the algorithm.

Topic 1.8. Work and powerThe work of constant force at a constant linear motion, units of measurement. The work of the resultant force. The work of gravity. The work during the rotational motion. The power, units of its measurement. The power rotary during motion of the body; circumferential force and rotational moment. Mechanical efficiency (efficiency).

Explanation of the main definitions and terms.Description of the methods of their determination.

The student should formulate and explain the definitions of "work", "power", "efficiency," and describe the methods of their determination.

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Contents of the topic Results Assessment criteriaSection 2. Strength of materials

Topic 2.1. Basic provisionsThe main objectives of the strength of materials: the notion of calculations for strength, rigidity and stability. Elastic and plastic deformation. Classification of external loads (static, dynamic, variable). The main hypotheses and assumptions used in the strength of materials: about the properties of a deformable body (homogeneousness, isotropy, the continuity of the structure); about the nature of the deformation (the principle of initial dimensions, the linear relationship between loads and deformations caused by loads, the principle of superposition). The classification of structural elements: beams, plates (shells), a massive body. The method of sections and its use to determine the internal force factors. Stress: full, normal, tangent.

Knowledge of the main objectives and provisions of the strength of materials.Communication of the hypotheses and assumptions, classification of the structural elements, description of the types of stress, and explanation of the essence of the method of sections.

The student should reveal the main objectives and provisions of the strength of materials, communicate hypotheses and assumptions, classify structural elements, describe the types of stress, and explain the essence of the method of sections.

Topic 2.2. Tension and compressionLongitudinal force. The hypothesis of plane sections (Bernoulli’s hypothesis). The normal stress in the

Knowledge of the main notions of tension and compression. Description

The student should describe the factors for origin of tension or compression, specify longitudinal forces and normal stresses and

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Contents of the topic Results Assessment criteriacross sections of beams. Building diagrams of the longitudinal forces and normal stress. Longitudinal and transverse deformation. Hooke's law. The modulus of elongation. Determination of the displacement of cross-sections. The coefficient of transverse deformation (Poisson's ratio).Testing materials for tension and compression under static loading. Load-extension diagrams of ductile and brittle materials. Mechanical properties of ductile and brittle materials: the proportional limit, yield strength (physical and conditional) and strength. Features of plastic properties: relative residual elongation at break and the relative residual narrowing.Allowable stress and the safety factor of yield strength and tensile strength. Calculations of strength: test, design, determination of allowable load.The method of calculating by limit states. Limit states and reliability of building structures. Safety factor for

of the deformation modes, Hooke's Law, and a stress-strain diagram.

build their diagrams, describe deformation modes, Hooke's Law, and a stress-strain diagram.The student should reveal the essence of allowable stresses and safety factor.The student should describe the calculation technique for the strength and formulate the condition of tensile (compression).The student should reveal the essence of the method of calculation for the strength by limit states.

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Contents of the topic Results Assessment criteriaload, material, purpose and operating conditions. Three types of strength calculations. Simple calculations for strength by limit states.

Practical work 8Calculation of statically determinated bar systems

Task solution for tensile (compression).

The student should produce the calculation of tensile (compression).

Practical work 9Calculation of constant cross-section bars.



Practical work 10Calculation of variable cross-section bars.



Topic 2.3. Shear and bearing stressShear and bearing stress: the basic design assumptions and formulas, imputation. The design resistance for a shear and bearing stress. Examples of calculation of riveted, bolted, welded joints based on the limit state.

Description of the main notions of shear and bearing stress. Calculation of riveted, bolted, welded joints based on the limit state.

The student should reveal the essence of the shear and bearing stress.The student should explain strength calculations at a shear and bearing stress.

Laboratory work 2Testing samples of various materials for shear and bearing stress.

Testing samples of various materials for shear and

The student should test the sample of various materials for a shear and bearing stress,

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Contents of the topic Results Assessment criteriabearing stress. calculate the strength characteristics and set the

material grade of the test sample, and prepare the test results.

Practical work 11Calculation for strength at a shear and bearing stress. Economic evaluation of the results obtained.

Solution of tasks for strength at a shear and bearing stress. Economic evaluation of the results obtained.

The student should produce all kinds of calculations for strength at the shear and bearing stress, analyze and control the practicability of the results obtained, perform economic evaluation, and draw strength calculations.

Topic 2.4. Torsion. Geometric characteristics of flat sectionsPure shear. Hooke's law in shear. Twisting moment diagrams. Torsion of the beam of the circular cross-section. Torque. Torque diagrams. Stresses and strains in the torsion of the beam of circular cross-section. The angle of twist. The polar moment of resistance for the circular and annular sections. Calculations for the strength and torsional rigidity. Choice of a rational section of the shaft in torsion.Geometric characteristics of flat cross sections of the beam. Moments of inertia: axial, polar and centrifugal. Axial moments of inertia of simple sections: rectangular, triangular, circular and

Description of the basic concepts of torsion. Explanation of the geometric characteristics of the plane section.

The student should reveal the essence of the shear, the shear modulus, torque, and torsional stress, describe building torque diagrams, explain the method for determining the strength and torsional rigidity, and prove the choice of a rational section of the shaft.The student should describe axis, polar, and centrifugal moments of inertia.The student should explain the relationship between the axial moment of inertia with respect to parallel axes, and specify the principal central moments of inertia of the composite sections.

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Contents of the topic Results Assessment criteriaannular sections.The relationship between the axial moment of inertia with respect to parallel axes. The principal axes and principal central moments of inertia. Determination of the main central moments of inertia of the composite section consisting of simple geometric squares and standard structural sections having an axis of symmetry.

Practical work 12Calculation for torsional strength. Economic evaluation of the results obtained.

Solution of tasks for torsion strength. Economic evaluation of the results obtained.

The student should produce all kinds of calculations for torsional strength, analyze and control the practicability of the results obtained, perform economic evaluation, and draw strength calculations.

Practical work 13Calculation of moments of inertia. Determination of axial moments of inertia of simple sections: rectangular, triangular, circular and annular. Comparison of the strength of shafts of different sections.

Solution of tasks for moments of inertia. Determination of axial moments of inertia of simple sections: rectangular, triangular, circular and annular. Comparison of the strength of shafts of different sections.

The student should calculate the moment of inertia, define the axial moments of inertia of the elementary sections, and compare the strength of shafts of different sections.

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Contents of the topic Results Assessment criteriaTopic 2.5. Bending. Curved bending

Types of symmetrical bending: pure and lateral. The internal power factors in symmetrical bending: lateral force and bending moment. Differential relationship between bending moment, lateral force, and intensity of distributed load. Building diagrams of lateral forces and bending moments. Basic rules for building diagrams. Normal stresses in bending.The derivation of the formula for normal stresses in pure bending at any point of the cross section of the beam. The stiffness of the section. Application of formulas obtained for pure bending to lateral bending. The concept of a section modulus. Zhuravsky’s formula for shear stresses in cross-sections of beams.Analysis of beams for the normal stress strength. Analysis of beams by the first group of limit states: checking the strength, the selection of the section, the definition of the bearing capacity. Rational cross-sectional shapes of beams of ductile

Explanation of the basic concepts. Revealing the essence of the rules of building of the various types of diagrams.

The student should reveal the essence of the concepts of "bending", "pure bending", "lateral bending," explain the rules for building diagrams of lateral forces and bending moments, develop a formula for the normal stresses, explain distribution over the cross section of normal and shear stresses, and present technique of performing calculations for the strength in bending in terms of normal and shear stresses.The student should explain the calculation for stiffness in terms of the second group of limit states.The student should explain unsymmetrical bending, and the distribution of normal stresses in the section, present the technique of the calculation for strength in unsymmetrical bending by the limit state.

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Contents of the topic Results Assessment criteriaand brittle materials.Calculation for the strength of beams for shear stresses. The concept of linear and angular displacements in symmetrical bending. Stringency condition and practical calculation for the beams by the second group of limit states using the predefined tables.Unsymmetrical bending: basic concepts and definitions. Power planes and lines. Normal stresses in the cross section of the bar. The calculation for the strength in unsymmetrical bending by the limit state. Determination of deflections.

Practical work 14Calculation of beams on strength in bending.

Calculation of beams on strength in bending.

The student should produce the calculation of beams on strength in bending.

Practical work 15Calculation of the stress in the beam cross section.

Calculation of the stress in the beam cross section.

The student should produce the calculation of the stress in the beam cross section.

Practical work 16Building diagrams of normal stresses.

Building diagrams of normal stresses.

The student should produce building diagrams of normal stresses.

Topic 2.6. Stability of centrally compressed bars

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Contents of the topic Results Assessment criteriaStable and unstable equilibrium states of centrally compressed bars. The phenomenon of buckling. Critical force and critical stress, slenderness ration of a bar. The limits of applicability of Euler's formula. Maximum flexibility. The empirical Yasinski’s formula. Calculations for the stability of centrally compressed bars by buckling factors. Rational cross-sectional shapes of compressed bars.

Description of the stable forms of centrally compressed bars.

The student should describe the stable and unstable forms of equilibrium of centrally compressed bars, the phenomenon of buckling, critical force, critical stress, flexibility, expand the limits of applicability of Euler's formula, explain the methodology for calculating the stability of compressed bars and a choice of rational cross-sectional shapes of compressed bars.

Test 2Section 3. Machine parts

Topic 3.1. Basic provisionsLinks, kinematic pairs, mechanisms, parts, assembly units. Classification of mechanisms. Requirements for machines, machine parts. The criteria of efficiency and calculation of machine parts.General information about gears. Purpose of mechanical gears and their classification according to the principle of action and on the basis of the motion transmission from the master to the slave unit. Basic kinematic and power relations in

Description of the main elements and mechanisms of the machine parts.Explanation of the methodology for performing the kinematic and power calculation of the drive.

The student should reveal the essence of the term "link", "kinematic pair", "mechanism", "part" and "assembly unit", explain the classification of mechanisms, criteria of efficiency of machine parts, explain the purpose of mechanical gears and present their classification.The student should explain the methodology for performing the kinematic and power calculation of the drive.

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Contents of the topic Results Assessment criteriagears. Kinematic and force calculation of the drive.

Topic 3.2. Types of gearsOverview of gears: operating principle, advantages and disadvantages, scope. Classification of gears. Basic theory of involute gear, the law of gearing. Gear of two involute wheels: the basic geometric characteristics of involute gearing. The calculation of the basic geometrical parameters of spur and helical gears.Brief information about the methods of manufacturing gear wheels. Types of damage to the teeth. Materials for gear wheels. Brief information about the calculation for contact strength.

Characterises the types of transporting.

The student should provide general information about gears, basic theory of gearing, describe methods of cutting teeth, and list the types of destruction of teeth.The student should explain the calculation of the basic geometrical parameters of spur and helical gears.The student should describe the device, operating principle, and classification, explain the use of the friction gear, and describe the types of materials for manufacture and types of destruction of working surfaces of rollers.The student should describe the device, the principle of worm gears, reveal their advantages and disadvantages, present and explain the classification of their scope.The student should characterize the types of destruction of teeth, describe materials for units, and explain the thermal design of the gear.The student should describe the device, the principle of belt gear operation, reveal their advantages and disadvantages, present and explain the classification of their scope.The student should compare gears with flat, cone, ribbed and tooth belts.

The device, working principle, classification of friction gearing, advantages and disadvantages, scope. Cylindrical gearing by plain rollers and normal operation condition. Gear ratio. Materials for rollers. Types of damages to working surfaces of rollers. Speed variators.

Description of the device, operation principle and classification of friction gears.

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Contents of the topic Results Assessment criteriaWorm gear: device, operating principles, advantages and disadvantages, scope. Classification of worm gears. The gear ratio, efficiency. Types of fracture of worm wheel teeth. Materials for units. Thermal design of the worm gear and worm gear cooling methods.

Description of the device, operation principle and classification of worm gears.

Belt gears: device, operating principles, advantages and disadvantages, scope. Classification of belt gears. Comparative characteristics of gears by flat, cone, ribbed, and tooth belts. Materials for their manufacture. Gear ratio.

Description of the device, operation principle and classification of belt gears.

Chain gears: device, operating principles, advantages and disadvantages, scope. Constructions of chain gear parts: sprocket chains, sprockets, tensioning devices. Comparative characteristics of gears by sleeve-type, roller, and toothed chains. Gear ratio. Normal operation criteria.

Description of the device, operation principle and classification of chain gears.

The student should describe the device, the principle of chain gears, reveal their advantages and disadvantages, present and explain the classification of their scope, and describe the structure of parts of chain gears.The student should communicate comparative characteristic of gears by sleeve-type, roller, and toothed chains.

Topic 3.3. Shafts and axles. Bearings. SocketsShafts and axis: purpose, classification. Structural elements,

Characteristics of shafts, axis, bearings and sockets.

The student should describe the purpose of shafts and axes, present their classification, and

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Contents of the topic Results Assessment criteriamaterials axle and shafts. Engineering and checking calculations.The classification of supports of shafts and axles. Plain bearings: design, advantages and disadvantages, scope. Materials. Types of destruction. Rolling bearings: design, advantages and disadvantages, scope. The classification of the functional loss causes.Purpose and classification of sockets. The main types of permanent, coupling, self-managed and safety sockets.

explain engineering and checking calculations of shafts.The student should explain the structure, classification and the scope of rolling beatings and plain bearings.The student should describe the purpose and the main types of sockets, and present their classification.

Topic 3.4. Joints of machine partsPermanent joints: welded, riveted, press fitted, soldered, and adhesive. Welded joints: classification by the location of welded elements and types of welds, features and scope. Riveted joints: classification, designs, features and applications. Press fitted joints: the advantages and disadvantages, scope. Soldered joints: materials for parts and solders. Adhesive joints: types of

Description of the types of permanent and detachable joints, their characteristics and scope.

The student should describe the types of permanent joints (welded, riveted, press fitted, soldered, and adhesive) and detachable joints (threaded, pin, keyed, and splined), their characteristics and scope. The student should explain the classification of joints.

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Contents of the topic Results Assessment criteriajoints, the adherence process. Detachable joints: threaded, pin, keyed, splined. Threaded joints: classification, basic types of fasteners. Pin joints: designs and types of pins. Classification of keyed and splined joints, their characteristics.

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of Engineering Mechanics, we recommend the following teaching forms: lectures, seminars, and laboratory work.



In presenting the program educational material it is required to observe the unity of terminology and symbols of technical values and dimensions in accordance with current standards and the International System of Units (SI).

Knowledge and skills obtained in the study of the academic discipline are necessary for further study of special academic disciplines, as well as for a successful practical training.

During the study of the academic discipline, the syllabus provides for laboratory and practical work.



- Quizzes - 2;- Passes - 1.Educational organizations must develop competence-oriented tasks


levels of complexity (minimum, medium and hard).Studying the academic discipline, the student mustknow the following:

- The role and importance of theoretical mechanics;- Basic notions of mechanics;- Main types of beam supports;- Classification of loads;- The conditions and the equations of equilibrium of material bodies;- Main points of strength of materials;- The methods of calculation for strength, rigidity and stability of

structures;- Types of gears; their structure, function, advantages and

disadvantages;- Kinematics of mechanisms, joints of machine parts.

be able to:

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- Use regulations and reference books;- Make calculations for compression, shear and bearing;- Make calculations of structural elements for strength, rigidity and

stability;- Choose a rational cross-sectional shape of beams;- Define the gear ratio.

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ELECTRO TECHNICS WITH THE BASICS OF ELECTRONICS

The purpose of the study of the academic discipline is to develop knowledge in the field of linear electric circuits of DC and AC single and three phase currents; non-linear electric DC circuits; magnetic circuits; transient electrical measurements; electromagnetism; transformers; electrical appliances; electrical machinery and apparatus, as well as the generation of knowledge about the production, distribution and consumption of electrical energy.

This academic discipline is a theoretical basis for the study of the following disciplines of the special cycle. Its study is based on a series of comprehensive training material and natural and mathematical sciences such as "Mathematics" and "Physics".


Section, topic

Number of hours

total

including those for

laboratory work

Introduction 11. Electric DC circuit 9 62. Electromagnetism 43. Electric AC circuits 8 64. Transformers 4 25. Electronic equipment and devices 8 66. Electrical appliances and their use 9 47. Electrical machines 8 68. Electric devices 4 2Test 19. Production, distribution and consumption of electric energy

4 2

10. Electrical Properties of Semiconductors 211. Semiconductor resistors 212. Semiconductor diodes 213. Transistors 214. Four-layer semiconductor devices (thyristors) 3

Total 72 34

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CONTENTS OF THE DISCIPLINEContents of the topic Results of training Assessment criteria

IntroductionBrief description and contents of the academic discipline, its relationship with other academic disciplines, significance for training qualified workers.Advantages of electrical energy.The role of electrification in the development of the socio-economic sector of the Republic of Kazakhstan.State and prospects of for energy development in the Republic of Kazakhstan. Energy and environmental issues.

Expression of a general judgment on the state of and prospects for energy development in the Republic of Kazakhstan, the aims and objectives of the subject, the role of electrification in the development of the socio-economic sector of the Republic of Kazakhstan.

The student should express a general judgment on the state of and prospects for energy development in the Republic of Kazakhstan, the aims and objectives of the subject, the role of electrification in the development of the socio-economic sector of the Republic of Kazakhstan.

Topic 1. Electric DC circuitElectric circuit. Elements of the electric circuit (source, user, connecting cables), basic laws, rules, equations and modes (Ohm's laws for the section of the electric circuit and the electric circuit, the first and second laws of Kirchhoff; the equation of power balance; the nominal mode; no-load and short-circuit conditions).Calculation of direct current electric circuits in series, parallel and mixed

The description of basic concepts of the electrical circuit of DC.

The student should explain the purpose of elements of the electric circuit, and name the elements of the electric circuit.The student should produce calculations of simple electrical DC circuits in accordance with the proposed algorithm, and equate based on the first and second laws of Kirchhoff.The student should explain the procedure for the calculation of

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Contents of the topic Results of training Assessment criteriacompound of consumers.The concept of non-linear electric DC circuits.

simple electrical circuits, and express a general judgment about the features of non-linear electric DC circuits.

Laboratory work 1The study of Ohm's law and its application in practice.

The student should describe Ohm's law and its application in practice.

The student should research modes of an electrical energy source.

Laboratory work 2The study of Kirchhoff’s laws. The student should describe Kirchhoff’s

law and its application in practice.The student should define the resistance value of resistors using color codes, and explore circuits with series-connected resistors.

Laboratory work 3The study of electrical DC circuits with mixed connection of resistors.

The student should describe electrical DC circuits with mixed connection of resistors.

The student should analyze electrical DC circuits with mixed connection of resistors.

Topic 2. ElectromagnetismMagnetic field and its main parameters: magnetic induction (B), magnetic field strength (H), the absolute permeability (µа), the magnetic constant (µо), relative permeability (μ), the magnetic flux (Ф).The phenomenon and electromoving force (EMF) of electromagnetic induction, self-induction and mutual induction, inductance, mutual

Knowledge of the basic concepts of the magnetic field and its parameters.

The student should define the basic parameters of the magnetic field, and reveal the essence of the phenomenon of electromagnetic induction, self-inductance and mutual inductance.The student should name basic parameters of the magnetic field, and express an overall judgment on the phenomenon of electromagnetic induction, self-inductance and

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Contents of the topic Results of training Assessment criteriainductance. Lenz's rule. Eddy currents. Losses of electricity in the eddy currents.The action of electromagnetic forces on the conductor and the circuit with current. Examples of the above phenomena in practice.

mutual inductance.The student should explain the essence of the action, and express a general judgment on the effect of electromagnetic forces on the conductor and the circuit with current.

Topic 3. Electric AC circuitsThe equations and graphs of sinusoidal quantities. Instant, peak, average and current values of EMF variables, voltages and currents. Their modification period, frequency, angular frequency, phase, initial phase, phase shift.Graphical representation of sinusoidal currents, voltages, EMF in the form of vector diagrams.Parameters of electric AC circuits (R, L, C): resistance and reactance.Physical processes in electric AC circuits with R, L, C with series-connected R, L and C. Vector diagrams. The calculated ratio. Resonance stress.Calculation of linear electric AC circuits. Physical processes in AC circuits in parallel connection of

Knowledge of the basic concepts of electric AC circuits. Making up equation and construction of the graph of the sinusoidal magnitude.

The student should formulate and name instantaneous, amplitude, current and average values of EMF variables, voltages and currents, their period of change, the electrical frequency and angular frequency, phase, initial phase, phase shifts, the parameters of electric AC circuits. The student should build vector diagrams. The student should explain physical processes in AC circuits with R, L and C with series-connected R, L and C. The student should express calculated ratio and explain the phenomenon of resonance voltage.The student should calculate linear electric AC circuits based on the given methodology, and reveal the nature of the physical processes in

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Contents of the topic Results of training Assessment criteriaresistance, inductance and capacitance. Vector diagrams. The calculated ratio. Current resonance.The power factor, ways to improve its economic viability.

AC circuits with parallel connection of R, L and C.The student should perform calculated ratio, explain the phenomenon of resonance currents, and build a vector diagram for series connection.

Obtaining the electromotive force (EMF) in a three-phase system. Connection of a three-phase system in the form of a "star" and "delta".Linear and phase currents and voltages, the ratio between them. The procedure for calculating the active (P), reactive (Q), total (S) power.

Knowledge of the principles of EMF. Making connection of the three-phase system.

The student should explain the principles of EMF producing in the three-phase system, the order of connection of the three-phase system in the form of a "star" and "delta".The student should know in general the peculiarities of obtaining EMF in the three-phase system, and distinguish the connections of the three-phase system in the form of a "star" and "delta" based on the obvious signs.The student should explain the calculated ratio line and phase currents and voltages when connecting as a "star" and "delta", the procedure for calculating the power P, Q and S.The student should recognize connections of electricity consumers of power in the form of a "star" and

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Contents of the topic Results of training Assessment criteria"delta" based on the obvious signs, and know in general in the relations between line and phase currents and voltages.

Laboratory work 4Learning basic concepts of alternating current technology and research in the ohmic resistance of the AC circuit

Learning basic concepts of alternating current technology and research in the ohmic resistance of the AC circuit

The student should analyze the ohmic resistance in the AC circuit

Laboratory work 5The study of serial and parallel connections of the inductor, resistor and capacitor

The study of serial and parallel connections of the inductor, resistor and capacitor

The student should analyze the serial and parallel connections of the inductor, resistor and capacitor.

Laboratory work 6The study of a circuit with a series connection of inductance and capacitance. Current resonance.

The study of a circuit with a series connection of inductance and capacitance. Current resonance.

The student should analyze circuits with a series connection of inductance and capacitance. Current resonance.

Topic 4. TransformersPurpose, principle of operation and the structure of a single-phase transformer. Its main parameters (transformation ratio, power factor, efficiency): the physical sense, the calculation based on formulas.Idle transformer. Operation of the transformer under load.Power losses in the transformer (electrical, magnetic). Determination

The student should characterize the principle of operation, structure of a single-phase transformer.Description of transformer operation.

The student should explain the principle of operation, structure of a single-phase transformer and its main parameters.The student should recognize in general in purpose and principle of operation of a single-phase transformer, name (with a prompt) its basic parameters in oral and written form.

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Contents of the topic Results of training Assessment criteriaof loss conducting idling and short-circuit tests.Three-phase transformers, their design and cooling systems.Special types of transformers (measuring, welding, pulse, autotransformers, etc.).

The student should explain the operation of a transformer in the idle and under load mode, describe the causes and location of electric and magnetic losses, the impact of various factors on the amount of losses, and explain the procedure for determining losses conducting idling and short-circuit tests.The student should explain the principle of operation of the three-phase transformers, their design and the cooling system.The student should explain express a general judgment (III) about the principle of operation of three-phase transformers, their design and the cooling system.The student should distinguish the main types of special transformers based on the obvious signs.

Laboratory work 7Experimental test of a three-phase transformer.

Testing of a three-phase transformer. The student should analyze the results of experiments.

Topic 5. Electronic equipment and devicesPhysical fundamentals of electronics. The movement of electrical charges in the electric and magnetic fields.

Description of the movement of electrical charges in the electric and magnetic fields, essence of electronic,

The student should explain the process of motion of electrons in electric and magnetic fields, the

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Contents of the topic Results of training Assessment criteriaElectronic, thermionic, and photoemission.Ionic devices with independent and non-self-discharge: neon lights, Zener diodes, gas-filled diodes, thyratrons. The principle of operation and scope.The main types of solar cells (photodiodes, photoresistors, photocells with a barrier layer). The principle of their operation and scope.Physical basics of semiconductor devices. The concept of the electron and hole conduction, electron-hole transition.Semiconductor diodes. Their current voltage characteristics, rectifying properties. Point and planar diodes. Silicon diodes and Zener diodes (reference diodes). Structure, types, parameters and scope.Semiconductor transistors with p-n-p and n-p-n structure. The main types of transistors, their characteristics (input and output) and scope.Switching circuits of transistors with common emitter, common base and common collector.

thermionic, and photoemission.Study of electronic devices and equipment.

essence of electronic, thermionic and photoemission.The student should express an overall judgment on the process of motion of electrons in electric and magnetic fields, and distinguish the features of electronic, thermionic, photoelectron emission based on the obvious signs.The student should communicate information, and express a general judgment about the structure of ionic devices, the main types of solar cells, the principle of action and scope.The student should reveal the essence of the electron and hole conduction, electron-hole transition.The student should communicate the purpose of semiconductor diodes, their rectifying properties, structure, types, parameters, scope, and current-voltage characteristics.The student should explain the construction of transistors with p-n-p and n-p-n structure, their characteristics, scope, switching circuits.

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Contents of the topic Results of training Assessment criteriaThyristors, their current-voltage characteristics; use in contactless switching circuits.Purpose and scope of rectifiers, smoothing filters, voltage regulators and current. Function diagrams of rectifying devices.The operational principle of a half-wave rectifier and full-wave rectifier, three-phase rectifiers, Г-, T, and П-shaped filters and stabilizersPurpose, classification, principle of operation, the scope of the semiconductor amplifiersThe concept of simple logic circuits (AND, OR, NOT); pulse circuits (flip-flop, multivibrator); integrated circuits and microprocessors.

The student should express a general judgment about the main types of transistors, particularities of their structure and scope.The student should explain the structure of thyristors, their current-voltage characteristics, and their application in non-contact switching circuits.The student should explain the purpose and scope of the rectifiers, smoothing filters and stabilizers of voltage and current, functional circuit of rectifying devices.The student should explain the principle of a half-wave rectifier, full-wave rectifier and three-phase rectifier, filters and stabilizers.The student should express an overall judgment on the purpose, classification, principle of operation, the scope of the semiconductor amplifiers.The student should name particularities of simple logic and pulse circuits, integrated circuits and microprocessors.

Laboratory work 8

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Contents of the topic Results of training Assessment criteriaStudy of the transistor operation with a common base and common emitter.

Ability to nalyze the transistor operation with a common base and common emitter.

The student should analyze the transistor operation with a common base and common emitter.

Laboratory work 9Study of the transistor operation with common emitter, common base and common collector.

Ability to analyze the transistor operation with common emitter, common base and common collector.

The student should analyze the transistor operation with common emitter, common base and common collector.

Laboratory work 10The study of inductive and capacitive resistance in an AC circuit.

Analysis of inductive and capacitive resistance in an AC circuit.

The student should conduct a comparison of inductive and capacitive resistance in an AC circuit.

Topic 6. Electrical appliances and their useTypes and methods of electrical measurements.Measurement errors. Accuracy class of measuring instruments.Classification of instrumentation and systems of their symbols.Analogue electrical measuring instruments (magneto-electric, electromagnetic, electrodynamic, induction, electrostatic, thermoelectric and rectifying). Their structure, operating principle and purpose. The ides of digital electrical measuring instruments. Purpose and

Knowledge of types and methods of electrical measurements, measurement errors, accuracy class of measuring devices.Classification of measuring devices and the system of symbols.Description of electrical measuring devices and determination of their scope.

The student should describe the types and methods of electrical measurements.The student should specify the measurement errors using the proposed method.The student should explain the concept, distinguish between the accuracy class of measuring devices, and explain the system of symbols.The student should explain the structure, the operating principle and purpose of analog and digital electrical measuring instruments,

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Contents of the topic Results of training Assessment criteriabasic principles of their construction.Measurement rules, switching circuits of an ammeter, voltmeter, power meter.Expanding the measurement limits of an ammeter, voltmeterMeasurement of resistance, inductance, capacitance, frequency, power factor, and the magnetic induction of the magnetic field.The idea of measuring non-electric variables by electric methods.Classification of transducers (sensors).

their scope.The student should recognize in general the purpose, structure, and scope of analog and digital electrical measuring instruments.The student should set out the rules for the measurement of values of current and voltage, and explain the rules of the power measurement.The student should calculate parameters of shunts and additional resistors to expand the measurement limits.The student should explain the rules and procedure for measuring the parameters of electric and magnetic circuits.The student should express an overall judgment on the measurement of parameters of electric and magnetic circuits.The student should explain features of measuring non-electrical values with the help of transmitters.The student should express a general judgment about the peculiarities of measuring non-electric values using measuring transducers.

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Contents of the topic Results of training Assessment criteriaLaboratory work 11

The study of the signal generator and oscilloscope

Ability to work with oscillograph. The student should explain the principle of operation of electrical circuits with an oscilloscope.

Laboratory work 12The study of the operation of electrical appliances (magneto-electric, electromagnetic, electrodynamic, induction, electrostatic, thermoelectric and rectifying).

Ability to work with electrical measuring devices.

The student should analyze the operation of electrical appliances (magneto-electric, electromagnetic, electrodynamic, induction, electrostatic, thermoelectric and rectifying). The student should explain the principle of operation of electrical appliances.

Topic 7. Electrical machinesThe structure of DC machines. The operating principle of a DC generator. Switching circuits of winding. External and regulation characteristics of the DC generator. The scope of the DC generator.The operating principle of the DC motor. Switching circuits of excitation winding. Mechanical characteristics. Methods of starting, reversion of speed, braking of DC motors.Three-phase asynchronous electric motors. The structure, operating

The study of electrical machines, their operational principle and scope.

The student should explain the structure of DC machines, operation of generators and DC motors and their scope.The student should express the features of switching circuits of winding to excite generators and DC motors; external and adjusting characteristics of the DC generator, the mechanical characteristics of DC motors.The student should explain methods of starting, reversion of speed, braking of DC motors.

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Contents of the topic Results of training Assessment criteriaprinciple, and scope. Power, rotational speed, sliding motion, rotational moment. Mechanical characteristics. Rotational speed control and change of the rotation direction (reverse). Methods of starting.Single-phase asynchronous motors. Their structure, operation and scope.

The student should express an overall judgment on the purpose, structure and scope of generators and DC motors, explain the purpose, structure and the operating principle of asynchronous three-phase motors, and describes the procedure for determining the power, rotational speed, sliding motion, and rotational moment.The student should explain the mechanical characteristic of the asynchronous motor methods of rotational speed control, reverse control, and methods of starting.The student should express an overall judgment on the purpose, structure, and scope of three-phase asynchronous motors.The student should explain the structure, the operating principle of single-phase asynchronous motors.The student should express an overall judgment on the purpose, structure, and scope of single-phase asynchronous motors.

The structure of the stator and rotor of synchronous machines.

The student should explain the structure of the stator and rotor of a

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Contents of the topic Results of training Assessment criteriaThe operating principle of a three-phase synchronous generator. External characteristic of a synchronous generator.The principle of operation of a synchronous motor. Mechanical characteristics of the synchronous motor. Barring methods, methods of rotational speed control and change of rotation direction (reverse). Scope.Synchronous condensers. Special electrical machines: tachogenerators; rotary amplifiers (RE); rotary transformers; synchro motors; stepper motors and linear motors.

synchronous machine, the operating principle of a synchronous generator and motor.The student should explain the external characteristic of the synchronous generator and mechanical characteristics of the synchronous motor, barring methods, methods of rotational speed control and reverse of the synchronous motor.The student should express an overall judgment on the purpose, structure of synchronous generators and motors.The student should explain the purpose, structure, and operating principle of special electric machines, their scope.

Laboratory work 13Experimental tests of the DC generator. Removing idling characteristics, exterior and control characteristics.

The study of the constant –current generator and idling characterization.

The student should analyze the results of experiments.

Laboratory work 14The study of the operation of three-phase asynchronous motor.

Ability to operate an asynchronous three-phase electric motor.

The student should analyze the operation of three-phase asynchronous motor.

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Contents of the topic Results of training Assessment criteriaLaboratory work 15

The study of the operation of synchronous generators and motors.

Ability to operate synchronous generators and motors.

The student should analyze the operation of synchronous generators and motors.

Topic 8. Electric devicesCommuting machines with manual and automatic action: knife switches, packet switches, push button switches, fuses, circuit breakers, GFI, emergency circuit breakers. Structure and operating principle.Methods of fire extinguishing of the arc.The structure and operating principle of electromagnetic relays, reed switches, thermal relays, time switches, photoelectric relays.Controllers, contactors and magnetic starters: their structure, operation, purpose, scope.

Description of the structure, the operating principle and purpose of switching and protective devices.

The student should explain the structure, the operating principle and purpose of switching and protective devices.The student should explain the ways to extinguish the arc when switching power circuits.The student should express a general judgment about the purpose, structure, scope of switching and protective devices.The student should communicate the structure and operation of the electromagnetic relay, reed switches, thermal relays, time switches, photoelectric relays.The student should explain the structure, the operating principle, purpose, and scope of controllers, contactors and magnetic contactors.The student should express a general judgment about the structure,

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Contents of the topic Results of training Assessment criteriaprinciple of operation and scope of controllers, contactors and magnetic contactors.

Laboratory work 16The study of the operation of a manual and automated switching device.

Ability to operate a manual and automated switching device.

The student should analyze the operation of a manual and automated switching device.

TestTopic 9. Production, distribution and consumption of electric energy

Forms of power. Comparative technical and economic characteristics of thermal, hydro and nuclear power plants.Electric networks. Cable and overhead power lines. Substations. Ways to reduce the power losses during transmission.Types of consumers. Power supply schemes for industrial and residential buildings. Switchgears.The concept of the electric drive; its functional circuit; classification of electric drives and their modes of operation; Load operation diagram; determination of power in continuous and intermittent modes; control methods of electric drives (relay-contactor, electric machinery,

Expression of the overall judgment on production, distribution and demand for electrical power.

The student should name the main types of power plants and their comparative technical and economic characteristics, methods of transmission of electric energy, reducing power losses in the process based on the obvious signs.The student should explain the power supply scheme different types of consumers, purpose, structure and principle of operation switchgears.The student should express an overall judgment on the power supply schemes for different types of consumers.The student should explain the device using the functional diagram and, the operation of the electric drive using load diagrams; basic

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Contents of the topic Results of training Assessment criteriathyristor).Power tools; their main types (drills, grinding tools, scissors, saws, etc.).Electric lighting. Incandescent and fluorescent lamps; their structure, operation and switching circuits.

modes of the operation of the device, the control methods for electric drives.The student should explain the principle of action and the purpose of the main types of the power tools.The student should communicate with a prompt the general information about the purpose and the use of power tools.The student should communicate with a prompt the general information about the structure and switching circuits for incandescent and fluorescent lamps.

Laboratory work 17Experimental test of the power tools of various types.

Description of the operation principle of the power tools of various types.

The student should analyze the results of experiments.

Topic 10. Electrical Properties of SemiconductorsThe internal structure of semiconductors. Covalent linkage of atoms in the crystal lattice of the semiconductor. Charge carriers in a semiconductor, the mechanism of their formation. Self and extrinsic conductivity of semiconductors. The temperature dependence of the conductivity of doped

Explanation of the electrical properties of semiconductors.

The student should explain the electrical properties of semiconductors.

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Contents of the topic Results of training Assessment criteriasemiconductors. P-n transition and its properties. Properties of the P-n transition in the presence of an external voltage. Current-voltage characteristic of the P-n transition.

Topic 11. Semiconductor resistorsThe basic definitions and classification of resistors. Thermistors, photoresistors, varistors, thermistors. Design features of semiconductor resistors, switching circuits. Parameters conditional graphic symbols, the marking of semiconductor resistors. Removing the characteristics and determination of parameters of semiconductor resistors.

Description of the characteristics of semiconductor resistors.

The student should set out the definition and classification of resistors, name and describe the design features of semiconductor resistors and switching circuits.

Topic 12. Semiconductor diodesThe basic definitions and classification of semiconductor diodes, rectifying diodes. Zener diodes. High-quality diodes, switching diodes, varicaps, tunnel diodes, photodiodes, light-emitting diodes, diode optocouplers. Design features, switching circuits, switching characteristics, parameters, conditional graphical symbols, and

Description of the characteristics of semiconductor diodes.

The student should set out the definition and classification of resistors semiconductor diodes, name and describe the design features of semiconductor diodes, switching circuits, switching characteristics, parameters, conditional graphical symbols, and marking.

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Contents of the topic Results of training Assessment criteriamarking. Removing the current-voltage characteristics of a semiconductor diode. The study of a silicon stabilitron.

Topic 13. TransistorsClassification, conditional graphic symbols and marking systems of transistors. Basic definitions. The structure and operating principle of bipolar transistors. Static characteristics of bipolar transistors to enable different schemes. Dynamic operational mode of bipolar transistors. Amplifying properties of bipolar transistors. The transistor as an active four-terminal network. Options of bipolar transistors. Temperature and frequency properties of bipolar transistors. The bipolar transistor in a mode key. The structure and operating mode of field effect transistors. Field effect transistors with the P-n transition. Field effect transistors with MIS (MOS) structure. Operational modes of field effect transistors, features and options of field effect transistors. Phototransistors. Triode

Description of the characteristics of transistors.

The student should set out the definition and classification of resistors of transistors, name and describe the design features of transistors, switching circuits, switching characteristics, parameters, conditional graphical symbols, and marking.

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Contents of the topic Results of training Assessment criteriaoptocouplers. Removing the statistical characteristics and the study of parameters of bipolar transistors in the circuit with the common base (CB). Removing the statistical characteristics and the study of parameters of bipolar transistors in the circuit with the common emitter (CE). The study of field effect transistors.

Topic 14. Four-layer semiconductor devices (thyristors)Basic definitions. Classification, conditional graphic symbols and marking systems of thyristors. Four-layer semiconductor structure and its features. Switching circuits, the characteristics and parameters of four-layer diodes and silicon-controlled rectifiers, optocouplers. The study of thyristors.

Description of the characteristics of four-layer semiconductor devices (thyrisitors).

The student should set out the definition and classification of resistors of transistors, name and describe the design features of thyristors, switching circuits, switching characteristics, parameters, conditional graphical symbols, and marking.

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GuidelinesTo implement the syllabus on the academic discipline Electrical

Engineering and Basic Electronics, we recommend the following teaching forms: lectures, seminars, and laboratory work.



To enhance the learning process it is required to make extensive use of visual aids, technical training aids. Lessons should be preferably carried out in a special lecture room equipped for use of technical means and conducting demonstrations.

In presenting the program educational material, you should use the International System of Units SI, conditional graphical symbols and rules for electrical circuits in accordance with the standards of the unified system design documentation (ESKD), the terms and definitions in accordance with applicable standards.





levels of complexity (minimum, medium and hard).Upon studying the academic discipline, the student should

know:- The main methods of obtaining, transmission by distance and the

practical use of electric power;- Methods of rational energy use;- Transients in electrical circuits;- Basic electrical and electromagnetic phenomena;- Physical nature of electric and electromagnetic phenomena;- Theoretical foundations of electrical engineering;- Patterns of construction and assembly of simple electrical circuits;- Conditional graphic symbols of elements of electrical circuits;- Units of electrical and electromagnetic quantities, methods and

means of measurement;- The operating principle of electrical appliances;

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be able to:- Interpret circuits, determine the purpose of the elements, and analyze

the modes of electrical circuits;- Make simple electrical circuits in series, parallel and mixed

compound of elements;- Perform simple calculations of electric circuits of direct and

alternating current;- Calculate and design a simple circuit circuits in accordance with the

technical specifications;- Choose electric devices in accordance with their purpose, and

perform electrical measurements.

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BASICS OF STANDARDIZATION AND METROLOGY

The purpose of teaching of the academic discipline is to provide students with the knowledge in the field of technical regulation, standardization, metrology and quality control, the system of technical regulation and standardization of the Republic of Kazakhstan.

The discipline is studied in close connection with other disciplines of the specialized and general trade cycles: "Fundamentals of Engineering Graphics", "Economy, Organization and Planning of Production", "Health and Safety" and others.


Section, topic

Number of hours

total

including those of practical

work1 2 3

Introduction 1Section 1. Fundamentals of Technical Regulation and Standardization

27 10

1.1. Basic concepts and definitions of technical regulation, standardization and quality control

5

1.2. The principles and methods of standardization 21.3. Standards bodies and offices 21.4. Normative legal acts in the technical regulation and standardization

8 4

1.5. Standard systems 6 41.6. Information provision in standardization 3 2Test № 1 1Section 2. Fundamentals of metrology 14 82.1. General information about metrology. Means of measuring

6 4

2.2. Measurement errors 6 42.3. Metrological services 2Section 3 Interchangeably 12 43.1. Interoperability. The uniform system of limits and hits. Basic concepts of the limit and seat

2

3.2. Limits and hits of smooth cylindrical joints 23.3. The accuracy of the form and arrangement of surfaces. The surface roughness.

4 2

3.4. Limits and hits of rolling bearings, threaded, splined and keyed joints.

4 2

Section 4. Fundamentals of product quality management 14 8

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1 2 34.1. The role of technical regulation and standardization to ensure product quality. The quality level assessment.

3 2

4.2. Quality control 5 4Test № 2 14.3. International cooperation in standardization, metrology and quality control of products and services

1

4.4. The legal basis of technical regulation and standardization.State supervision over the observance of technical regulations and measuring instruments

4 2

Total 68 30

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IntroductionThe purpose and content. The relationship between the technical regulation and standardization, metrology, compliance conformation and quality control. The role and place of the discipline in the professional training system.A brief overview of the standardization development.

The student should express an overall judgment on technical regulation and standardization, metrology, quality control of products and compliance conformation, their role and place in the production management.

The student should express an overall judgment on technical regulation and standardization, metrology, quality control of products and compliance conformation, their role and place in the production management.

Section 1. Fundamentals of Technical Regulation and StandardizationTopic 1.1. Basic concepts and definitions of technical regulation, standardization and quality control

Purpose and content of standardization and metrology.Standardization and metrology relationship with other areas of knowledge.The idea of the role of the subject when training professionals of a set level and mid-level professionals.Kazakhstan has a state system of standardization (GSS), which unites and organizes the standardization work in the whole country, at all levels of production and management based on a set of state standards.Standardization is an activity aimed at

Knowledge of the basic concepts of and definitions of technical regulation, standardization and quality management.

The student should reveal the essence of the concepts on the state system of technical regulation, aimed at ensuring of safety of products, services and processes in the Republic of Kazakhstan.

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Contents of the topic Results Assessment criteriaachieving of the optimal level of organization of requirements for products, services and processes by establishing of provisions for general, repeated and voluntary use in respect of actual and potential problems.

Topic 1.2. The principles and methods of standardizationPrinciples and methods of standardization.Consistency, completeness, prospects, optimization, interoperability, interconnection of standards.Aggregation, unification, typing.Preferability, the system of preferred numbers, parametric ranks.Comprehensive and advanced standardization, forecasting. Economic efficiency of the standardization. The notion of common requirements for the formation and construction of cross-industry complexes of general technical state standards. Composition and purpose, the general requirement of interbranch complexes as basic organizational and technical, non-state general technical standards.

The student should characterize the principles and methods of standardization.

The student should express an overall judgment on the main goals and objectives of the technical regulation and standardization, reveal the essence of the principles and methods of standardization, and explain their importance and the need for the production of products.

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Contents of the topic Results Assessment criteriaObjects of standardization. Categories and types of standards. Guidelines and recommendations for standardization.The procedure for the development, review and implementation of norms and specifications.Specifications for handling, building, and road machines and equipment.

Topic 1.3. Standards bodies and officesThe main tasks of the Standard Committee and the system of its services.The concept of enterprise standards. The main provisions of the enterprise standard. Conduct of Examination of compliance with regulatory documents.Standardization bodies and services. Standard services for matters of the economy sectors and their tasks.Departments of standardization in enterprises, their structure, functions and powers.

Statement and description of the standards bodies and offices.

The student should distinguish different levels of standardization.The student should name the main standardization bodies and services in the Republic of Kazakhstan, their functions and tasks.The student should reveal the relationship between the levels of the standardization and functions of standardization bodies and services.

Topic 1.4. Normative legal acts in the technical regulation and standardizationNormative legal acts in the field of technical regulation and standardization:- Technical regulations;- Standards, including national standards,

Description of normative legal acts in the technical regulation and standardization.

The student should describe the regulations depending on the approval level and dissemination, and determine the form of regulations according to the content of requirements set upon them.

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Contents of the topic Results Assessment criteria- Standards organizations.The procedure for development, approval, implementation of the standards.Forms of standards: basic standards; standards for products, processes, services; control method standards; standard for terms and definitions.The procedure for the implementation of and compliance with technical regulations.

The student should outline the development and application of technical regulation in the technical regulation and standardization.

Practical work 1

The study of the normative regulations in the area of technical regulation and standardization used in the industry.

The study of the normative regulations in the area of technical regulation and standardization used in the industry.

The student should classify the normative regulations by types, and use technical regulations applicable in the industry.

Topic 1.5. Standard systemsPurpose and content of standards systems: Unified System Design Documentation (ESKD), Unified System of Technological Documentation (ESTD), Safety Standards Systems (SSBT), State System for Ensuring the Uniformity of Measurements (GSI), ISO 9000 standards systems and others.

The student should characterize the most important systems of standards; express an overall judgment about their purpose and content.

The student should name the most important standards, express an overall judgment about their purpose and content, and distinguish standards by their designation.

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The study of the necessity and the importance of using different systems of standards for interoperability related industries.

The student should study the necessity and the importance of using different systems of standards for interoperability related industries.

The student should characterize the most important standards, their purpose and content.

Topic 1.6. Information provision in standardizationThe purpose of information publications in standardization.Index of national standards of the Republic of Kazakhstan, Monthly index of national standards of the Republic of Kazakhstan, Index of normative documents GOST, the procedure for their use.The procedure for the acquisition of the normative regulations.

The student should describe the basic information publications; explain the purpose of the Indexes, their structure and rules to use them to find the right information, the procedure for acquiring the normative regulations.

The student should describe the basic information publications in standardization and reveal their purpose.The student should explain the purpose of the Indexes, their structure and rules to use them to find the right information, the procedure for acquiring the normative regulations.

Practical work 3The study of information publications in standardization.

The student should study information publications in standardization.

The student should produce the search of normative regulations, and check of normative regulations by the Indexes.

Test № 1Section 2. Fundamentals of metrology

Topic 2.1. General information about metrology. Means of measuringThe history of the metrology development as a science. The role and place of metrology in production. The notion "measurement". The role of metrology in the quality assurance.

The student should express a general judgment about the development of metrology as a science, the aims and objectives of metrology and its role in improving the quality of products.

The student should express a general judgment about the development of metrology as a science, the aims and objectives of metrology and its role in improving the quality of products.

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Contents of the topic Results Assessment criteriaMeasuring control.Physical and non-physical quantities, their measurements. Evaluation of the properties, the scale of properties. Types of scales: of names, order, intervals and relationships. The absolute scale. Application of scales.Types of measurements. Methods of measurement. The method of direct estimation. The method of comparison with a measure, its types.Quality of measurements. Precision, accuracy, repeatability and reproducibility of measurements. The reliability of measurement results. Equally accurate and unequal accurate, reversionary and non- reversionary measurements.Types of measurement. Classification of measurements.Basic metrological characteristics of measurements. Private metrological characteristics: the multiplying factor, limits and range of transformation, limits and range of the reading (scale range), limits and range of measurements, the output code, the number of bits of code, the nominal unit

The student should know the general data on metrology and measuring tools.

The student should reveal the essence of the basic concepts of metrology, and explain the role of measurements in the production process, the classification of measurements, their scope and the basic functions of measurements, and basic metrological characteristics of measurements.

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Contents of the topic Results Assessment criteriaprice of the least digit code, the nominal level of quantization. The errors of measurement, rationing.

Practical work 4Measurement of a physical value (PV). The unit availability. The possibility of comparison of a PV with the unit. The basic equation of measurements.

The student should measure the physical value. Characterizes the main equations for measurements.

The student should measure the physical value. Characterizes the forms and methods of measurements, quality requirements for measurements.

Topic 2.2. Measurement errorsBasic concepts: the measurement error, measurement accuracy, correct measurement, repeatability and reproducibility of measurements.Classification of measurement errors. Sources of errors. Systematic, random and gross errors. Static and dynamic errors. Significant and negligible errors.Methods to improve the quality of measurements. The analytical and experimental methods of detecting errors. Finding errors in information sources.

The student should name the main errors of measurements.

The student should explain the causes of the errors and the need to consider them in the processing of the measurement results.The student should describe the classification of errors.

Practical work 5The study of methods and techniques to reduce and exclude errors. Preventing errors.

The student should study the methods and techniques to reduce and exclude errors. Preventing errors.

The student should analyze the causes of errors and methods to reduce them.

Topic 2.3. Metrological services

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Contents of the topic Results Assessment criteriaThe essence and purpose of the metrological services. The challenges facing the state metrological service and the metrological service of the enterprise.Metrological provision of production: the essence and the provision procedure.

The student should name the functions and goals of the state metrological service and the metrological service of the enterprise.

The student should name the functions and goals of the state metrological service and the metrological service of the enterprise.

Section 3. InterchangeablyTopic 3.1. Interoperability. The uniform system of limits and hits. Basic concepts of the limit and seat.

The concept of interoperability. Basic concepts and definitions: the mating and free surface of parts. The covered and covering size of the coupling: nominal, real and ultimate sizes. Deviations, dimensional limits. Conditions of real size readiness. Graphical representation of the limit range.Application of limit deviation symbols to the design drawings of products.

Knowledge of the basic concepts of interoperability, the uniform system of limits and hits, the basic concepts of limits and hits.

The student should explain the concept of interoperability, the mating and free surface of parts, and explain the graphical representation of limit ranges and the application of the limit deviation symbol on the design drawings of products.

Topic 3.2. Limits and hits of smooth cylindrical joints.The concept of a unified system of limits and hits for smooth cylindrical joints.Hole systems. Characteristics of the hole. Location of the limit range of the main hole relative to the nominal size. Location of the hole limit range depending on the seat. The advantage of

Knowledge of the basic concepts of limits and hits of cylindrical joints.

The student should explain a unified system of limits and hits for smooth cylindrical joints.The student should characterize the advantage of the hole.The student should describe the shaft system and the location of the hole limit

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Contents of the topic Results Assessment criteriathe hole system.Shaft systems. Characteristics of the shaft. Location of the limit range of the main shaft relative to the nominal size. Location of the hole limit range depending on the seat.Hits in the hole system and in the shaft system.Types of hits. The class of accuracy. The degree of precision in manufacturing parts – the class of accuracy, maximum and minimum clearances and tension. Limit range table at nominal sizes from 1 to 500 mm.Graphical representation of limits and seat in the hole and shaft systems.

range depending on the seat.The student should describe the types of hits, the class of accuracy, the degree of precision in manufacturing parts – the accuracy degree, maximum and minimum clearances and tension. Limit range table at nominal sizes from 1 to 500 mm.

Topic 3.3. The accuracy of the form and arrangement of surfaces. The surface roughness.The concept of the surface deviations. Validity condition at malfunctioning of the geometric form for the admission of the base size. Identification and definition of form limits and the part surface location. Classification of deviations and form limits, and surface arrangement. Symbols in the drawings.Definition of roughness. Influence of surface roughness on the surface quality. Roughness parameters and surface

The student should characterize the accuracy of forms and surface roughness. Description of the surface arrangement.

The student should classify deviations, form limits and surface arrangement, and describe roughness, roughness classes and surface roughness symbols.

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Contents of the topic Results Assessment criteriaroughness symbols. Roughness classes. The surface roughness symbols and rules for applying them to the drawings.

Practical work 6Studying of tolerances of the mold, location and surface roughness.

The student should study tolerances of the mold, location and surface roughness.

Decrypts the requirements for accuracy of the mold, location and surface roughness.

Topic 3.4. Limits and hits of rolling bearings, threaded, splined and keyed joints.Types of loading of rolling bearings. Features of limits and hits of rolling bearings. Limit ranges of shafts and holes for connection to the bearings.Accuracy class of rolling bearings and their choice. Location of limit ranges of outer and inner rings of rolling bearings. Selection of rolling bearing hits on the shaft and the housing. The requirement for the accuracy of the shape and roughness of the seating surfaces of shafts and holes of buildings. Symbols for hits of rolling bearings in assembly drawings.The concept of the principles of ensuring the interchangeability of cylindrical threads.Basic parameters of cylindrical threads: step, profile angle, the outer, middle and inner diameters.

The student should describe limits and hits of rolling bearings, threaded, splined and keyed joints.

The student should describe accuracy classes of rolling bearings and their choice.The student should characterize the principles of ensuring the interchangeability of cylindrical threads.The student should describe the basic parameters of cylindrical threads: step, profile angle, outer, middle and inner diameters.The student should identify and indicate the elements of the thread, characterize the classes and the accuracy degrees of metric threads, and name the limit range of the thread, the limit systems and the systems of hits of metric threads.

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Contents of the topic Results Assessment criteriaDefinition and identification of thread elements. The classes and the accuracy degree of metric threads. Thread limit range. Systems of limits and hits of metric threads.Clearance, interference and transition fits. Application of clearance, interference and transition fits. Symbols for accuracy and metric thread fits in the drawings.Systems of limits and fits for plastic parts. Systems of limits for the plastic thread.The notion of the types of slotted and keyed joints.The main parameters of splines. Methods of centering splines.Limit ranges recommended for sided slotted parts. Symbols for splined joints in the drawings.

Practical work 7

Graphical representation of keyed joints with a parallel key. Selection of the key depending on the diameter. Determining of the keyed joints, the limit range used for keyed joints with a parallel key.

The student should graphically represent keyed joints with a parallel key. Description of selection of the key depending on the diameter. Determination of the keyed joints, the limit range used

The student should explain the choice of keys depending on the diameter, type of keyed joints, and depict keyed joints with a parallel key.

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Contents of the topic Results Assessment criteriafor keyed joints with a parallel key.

Section 4. Fundamentals of product quality managementTopic 4.1. The role of technical regulation and standardization to ensure product quality. The quality level assessment.

Standardization as a science, its role in the product quality management.The product life cycle. The role of standards at every stage of the product life cycle.Problems of quality management nowadays.The level of product quality.Classification of quality product indicators. Industrial and consumer indicators of the products quality, and their characteristics.The quality level assessment. The main stages of the quality level assessment.Methods for assessing the level of quality: differential, integrated, and mixed.Highest, satisfactory and optimum level of products quality.

The student should characterize the role of technical regulation and standardization to ensure product quality.

The student should set out the main objectives set by the direction of the Republic of Kazakhstan in improving the quality of products.The student should explain the concept of products quality level, classification of quality indicators, describe each group of quality indicators, and set out the methods for determining the level of products quality.

Practical work 8The study of the quality state policy. The student should study the quality state

policy.The student should explain the purpose of the state policy in the field of quality.

Topic 4.2. Quality controlThe main goals of quality control.Types of control used in the production

The student should know the main goals of quality control and the types of control

The student should explain the purpose of quality control, set out its main task,

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Contents of the topic Results Assessment criteriaand operaton of products. Organization of quality control in the company based on its standards.

used in the production and operation of products.

and describe the types of quality control, scope, procedure for organization of technical control in the enterprise.

Practical work 9The student should study the normative legal acts used for quality control of products (works and services) and for technical control in the company.

The student should study the normative legal acts used for quality control of products (works and services) and for technical control in the company.

Applies statutory and regulatory enactments to verify the quality of end products (works, services) of various assortments.Analyses the quality of goods (works, services) subsequent to the results of the technical control.

Test № 2Topic 4.3. International cooperation in standardization, metrology and quality control of products and services

The role of international cooperation in standardization, metrology, quality control of products and services. World Trade Organization (WTO). The requirements of the WTO agreements on TBT and SPS in terms of standardization and technical regulation. International organizations for standardization: International Standardization Organization (ISO), International Electrotechnical Commission (IEC).Regional organizations for standardization: European Committee for Standardization (CEN), European

The student should know the main organizations of the international and regional standards: ISO, IEC, CEN, CENELEC, etc., and express a general judgment about the features of the development of standardization in the various countries of the world.

The student should name main organizations of the international and regional standards: ISO, IEC, CEN, CENELEC, etc., and express a general judgment about the features of the development of standardization in the various countries of the world.

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Contents of the topic Results Assessment criteriaCommittee for Electrotechnical Standardization (CENELEC). Economic Commission for Europe (UNECE). EU activities in the field of standardization.National standardization abroad (experience of foreign countries in the field of standardization).Cooperation of the Republic of Kazakhstan with international, regional and national organizations of other countries in the field of standardization.International and regional certification.International and regional organizations on metrology.

Topic 4.4. The legal basis of technical regulation and standardization.State supervision over the observance of technical regulations and measuring instruments

The purpose of state supervision bodies, the main goals of state supervision. Its structure and basic functions.Government regulations in the field of the state supervision over the quality of products and services.The forms of the state supervision, the effectiveness of their application.The value and role of law On Technical Regulation and Standardization, On Ensuring the Unity of Measurements, On the Assessment of Compliance with

The student should know the legal basis of the technical regulation and standardization.

The student should explain the purpose of the state supervision and its main goals and functions.The student should reveal the role of laws On Technical Regulation and Standardization, On Ensuring the Unity of Measurements, On the Assessment of Compliance with Requirements of Technical Normative Legal Acts in Technical Regulation and Standardization to provide quality of products and services.

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Contents of the topic Results Assessment criteriaRequirements of Technical Normative Legal Acts in Technical Regulation and Standardization.

Practical work 10The study of the role of laws, duties and responsibilities of manufacturers and sellers of consumer goods.

The student should study the role of laws, duties and responsibilities of manufacturers and sellers of consumer goods.

The student should set out the basic laws, and characterize the duties and responsibilities of the manufacturers of goods and services.

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of Standardization and Metrology, we recommend the following teaching forms: lectures, seminars, laboratory and practical work.



When presenting the educational material, it is required to observe the unity of terminology and symbols in accordance with the standards, be guided by the System of Technical of the Republic of Kazakhstan, the legislation on technical regulation, standardization and product quality.

The program provides for practical work by separate topics to secure the acquisition of theoretical knowledge and ability to work with the normative legal acts (technical regulations) in the field of technical regulation and standardization. We suggest excursions to companies.





levels of complexity (minimum, medium and hard).Upon studying the academic discipline, the student should

know the following:- Basic concepts, terms and definitions of metrology, technical

regulation and standardization, conformity assessment and quality control;- Types of standards used in professional activities;- The accuracy system of the geometric parameters;- Method of calculation of limits and fits of parts;- Types, purpose and function of means of measurements.be able to:- Use information publications on standardization;- Apply the standards in practice;- Determine the size, deviations and limits of parts and their joints;- Identify limiting gaps and interference of the joint;- Use the technical means of measurement.- Use standards and specifications indexes;

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- Apply the necessary technical regulations and other documents on standardization for the task;

- Use the list of limits reducing quality indicators;- Control parameters when checking the quality of products at all

stages of production;- Classify the types of defects and relate them to a specific group and

the technological stage of production, at which they could occur.

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METAL TECHNOLOGY AND WELDING

The purpose of the study of the academic discipline is to study the issues of technology of production of ferrous and non-ferrous metals, fundamentals of metallurgy and heat treatment, the industrial use of the basic structural and tool materials, methods of machining and welding.

The study of the academic discipline Metal Technology and Welding is based on the knowledge gained by students in the course of studying such disciplines as "Chemistry", "Physics", "Structures", and "Fundamentals of engineering drawing."


Section, topic

Number of hours

total

IncludingThose for laboratory

work

Those for practical work

1 2 3 4Introduction 1Section 1. Fundamentals of metallurgy

35 14 4

1.1. The structure, properties of metals and their test methods

8 6

1.2. The main provisions of the theory of alloys. The alloys of iron with carbon

6 4

1.3. Carbon steel 4 21.4. Cast iron 3 21.5. Fundamentals of heat and chemical heat treatment

8 2

1.6. Alloy steel and hard alloys 4 21.7. Non-ferrous alloys. Corrosion of metals

1

Test № 1 1Section 2. Production of ferrous and nonferrous metals

8

2.1. Cast iron production 32.2. Steel production 22.3. Production of non-ferrous metals 2Section 3. Production of non-ferrous metals

14

3.1. Foundry 63.2. Pressure treatment 23.3. Machining 6Section 4. Welding and cutting metals 28 12

159

1 2 3 44.1. General information about the welding production. Physical fundamentals of welding. Power supplies, accessories and tools for welding

2

4.2. Manual arc welding 6 44.3. Automatic and mechanized submerged arc welding. Gas-shielded welding

4

4.4. Arc cutting 44.5. Contact welding. Gas welding and cutting

8 6

Test № 2 14.6. Welding defects and its quality control

3 2

Total 86 14 16

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IntroductionGoals and objectives of the discipline "Metal Technology and Welding", its relationship with other disciplines, of the special cycle, the value in the system of professional training.The value of metals in modern industry and technology, and their rational utilization.The current state of production of ferrous and non-ferrous metals. Development prospects of ferrous and non-ferrous metallurgy.The role of domestic and foreign scientists in the development of metal science and metallurgy.

The student should express a general judgment about its value in the preparation of the expert, the meaning and the rational use of metals in modern technology, the current state and development prospects of metal science and metallurgy.

The student should name the goals and objectives of the discipline, express a general judgment about its value in the preparation of the expert, the meaning and the rational use of metals in modern technology, the current state and development prospects of metal science and metallurgy.

Section 1. Fundamentals of metallurgyTopic 1.1. The structure, properties of metals and their test methods

Amorphous and crystalline substance. The crystalline structure of metals. The unit cell of the crystal. Main types and parameters of spatial lattices of metals. Defects in the structure of real crystals.Crystallization of metals. Primary and secondary crystallization. The structure of the metal ingot. Graphs of heating and cooling of metals.

The student should describe the main structures, properties of metals and their test methods.

The student should describe the amorphous and crystalline structure of metals, basic types and parameters of crystal lattices.The student should reveal the essence of the processes of crystallization of metals, polymorphic transformations.The student should explain the

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Contents of the topic Results Assessment criteriaThe anisotropy of the properties of crystals.Polymorphic transformation and magnetic metals. The cooling curve of iron.The basic properties of metals: physical, chemical, mechanical, technological. Mechanical testing of metal for strength, hardness, toughness, fatigue strength. The main types of technical tests. Physical methods of research of metals: macro analysis, microanalysis, X-ray, ultrasound, thermal and other methods.

construction of the cooling curves of metals.The student should describe the basic physical, chemical, mechanical and technological properties of metals, types of technical tests and physical methods of research of metals.

Laboratory work 1Determination of the hardness of metals and alloys based on the Brinell’s method.

The student should determine the hardness of metals and alloys based on the Brinell’s method.

The student should determine of the hardness of metals and alloys based on the Brinell’s method.

Laboratory work 2The impact strength test of metals. The student should perform an

impact test of metals.The student should perform an impact test of metals.

Laboratory work 3The fatigue strength test of metals. The student should perform a test on

the fatigue strength of metals.The student should perform a test on the fatigue strength of metals.

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Contents of the topic Results Assessment criteria

Topic 1.2. The main provisions of the theory of alloys. The alloys of iron with carbonThe alloy, component, systems, the phase. Methods for preparing alloys. The main types of alloys: a mechanical mixture, solid solution, and chemical compound; conditions of their formation and properties.Binary alloy phase diagrams. The main types of alloy constitution diagrams, the principle of their building. The phase rule. Critical points, lines of liquidus, solidus, and eutectic.The simplified iron-cementite phase diagram. Structural components: ferrite, austenite, cement, perlite, ledeburite, their brief characteristics. Features of construction, main lines and points of the Fe−Fe3C diagram.An analysis of transformations in iron-carbon alloys of different composition during heating and cooling in accordance with the iron-cement diagram.Classification of iron-carbon alloys, commercial iron, steel, and white cast irons.

The student should characterize the main provisions of the theory of alloys. Description of the alloys of iron with carbon.

The student should describe the types, structure, methods of preparation, conditions of formation and properties of the alloys.The student should reveal the essence of the alloy phase diagrams, and explain the principle of their construction.The student should produce the construction of the cooling curves of binary alloys.The student should describe the phase iron-cement diagram, and characterize the main structural components of the iron-carbon alloys (ferrite, austenite, cement, perlite, ledeburit).The student should describe explain alloy phase transformations occurring during cooling.

163


Building alloy phase diagrams. The student should produce building alloy phase diagrams.

The student should produce building alloy phase diagrams.

Practical work 2Building cooling (heating) curves in accordance with Fe−Fe3С diagram followed by the analysis of the occurring processes.

The student should build the cooling (heating) according to the diagram Fe−Fe3С with the analysis of the occurring processes.

The student should produce building the cooling curves for a given iron-carbon alloy, and analyze occurring processes.

Topic 1.3. Carbon steelClassification of steels: by the method of manufacture, carbon content, structure, purpose, quality, and degree of deoxidation.Influence of carbon and permanent impurities on the properties of steels. Carbon structural steel of ordinary quality and of high quality: the composition, properties, marking, and scope.Tool carbon steel: classification, composition, properties, marking, and scope.

The student should describe classification of steels: by the method of manufacture, carbon content, structure, purpose, quality, degree of deoxidation and scope.

The student should communicate the classification, describe the structure and properties of carbon steel, and explain the scope of structural and tool carbon steels.The student should reveal the peculiarities of carbon steel marking.

Laboratory work 4Test on carbon steel properties. The student should test carbon steel

and its properties.The student should conduct a test on carbon steel properties.

Topic 1.4. Cast ironThe classification of cast iron: by production method, carbon phase,

The student should characterize cast iron.

The student should describe the types of cast iron, its composition,

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Contents of the topic Results Assessment criteriagraphite inclusion form, and the structure of the metal base. Influence of carbon and regular impurities on the cast iron properties.White cast iron, their structure, properties, and scope. Gray cast iron: properties, branding, and scope. Modification of gray cast iron, their structure.High-test cast iron: production, structure, properties, branding, and scope.Malleable cast iron: production, properties, purpose. Malleable cast iron branding.

structure, mechanical and technological properties, and scope.The student should name the peculiarities of branding of gray, malleable and high-test iron.

Laboratory work 5The study of the microstructure of iron-carbon alloys in equilibrium.

The student should study the microstructure of iron-carbon alloys in equilibrium.

The student should analyze the microstructure of iron-carbon alloys.

Topic 1.5. Fundamentals of heat and chemical heat treatmentNature and purpose of the heat treatment, its types. Factors influencing the heat treatment mode. Transformations occurring in steel during heating. Isothermal transformation of austenite.Annealing: types, purpose, and technology. Effect of annealing on the properties of the steel.Normalization of steel: nature,

The student should describe the main method of heat and chemical heat treatment.

The student should reveal the essence and purpose of heat treatment of steel.The student should describe hardening technology, tempering, annealing and normalizing of steel, the equipment used. The student should explain the effect of types of heat treatment on the

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Contents of the topic Results Assessment criteriaimplementation technology. Structure and properties of annealed steel.Hardening of steel: nature, purpose, implementation technology. Methods for hardening. Temperature selection for steel hardening, coolants. The critical hardening rate. The refrigeration treatment of hardened steel. Surface steel hardening.Tempering: nature and types. Effect of tempering on the properties of steel.Implementation of hardening and tempering of carbon steel.The essence and purpose of chemical and heat treatment of alloys. The main types of chemical heat treatment: carburizing, nitriding, carbonitriding, and nitrocarburizing.

structure and properties of steel.The student should reveal the features of the main types of chemical and heat treatment of steel and explain their effect on the properties of steel.

Laboratory work 6Hardening and tempering of carbon steel. The student should describe the

modes of hardening and tempering of carbon steel.

The student should assign modes of hardening and tempering of steel, and analyze the microstructure and hardness of the steel before and after heat treatment.

Topic 1.6. Alloy steel and hard alloysAlloy steel. Alloying elements and their effect on the properties of steel.

The student should characterize alloy steel and hard alloys.

The student should describe alloy steel, and explain the effect of

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Contents of the topic Results Assessment criteriaClassification of alloy steel by chemical composition, structure, quality and content of alloying elements and scope.Low alloy steel used in the production of construction products and designs. Reinforcing steel, its classification, properties and purpose. Branding of alloy steel.Alloy tool steel, its composition, properties, and scope. High-speed steel, its properties and characteristics of the heat treatment.Alloy steel with special physical and chemical properties: corrosion-resistant, corrosion-resistant, heat-resistant, acid and other: the properties, composition, and scope.Cemented carbide alloys: structure, production, properties, and scope. Branding of hard alloys.Powder metallurgy and sprayed coatings.Amorphous metals. Shape-memory alloys.Composite materials with a metal matrix.

alloying elements on the properties of steel.The student should explain the classification of alloy steel by chemical composition, structure, quality and content of alloying elements, and scope.The student should describe the structure and properties of low-alloy structural steel, including those of reinforcing-bar steel, and explain the features of their application and branding.The student should name basic types of tool steel, including those of high-speed steel, steel with special properties; cemented carbide alloys, and distinguish their properties and branding.

Laboratory work 7The study of the microstructure of alloy steel.

The student should describe the microstructure of alloy steel.

The student should analyze the microstructure of alloy steel.

Topic 1.7. Non-ferrous alloys. Corrosion of metals.

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Contents of the topic Results Assessment criteriaCopper base alloys (brasses and bronzes), their classification, composition, properties, characteristics and scope.Aluminum-based alloys. Cast and wrought aluminum alloys. Silumins, their structure, properties and scope. Duralumin, its composition, properties and scope. Heat treatment of duralumin, its use in construction. Branding of aluminum alloys.

Bearing alloys. The composition, purpose and branding of babbitt metals.The essence of the corrosion of metals and alloys. Types of corrosion and the factors influencing the rate of its flow.Ways of protecting metals and alloys from corrosion: metallic and nonmetallic coatings, electrochemical protection, sacrificial protection.Modern methods of corrosion protection of embedded parts in concrete products and structures.

The student should describe the properties, branding and scope of aluminum and copper alloys.The student should describe the process of corrosion metal damage.

The student should describe the properties, branding and scope of aluminum and copper alloys.The student should decrypt the branding of aluminum, copper and their alloys.The student should reveal the essence of the corrosion of metals and alloys.The student should describe the process of corrosion metal damage, modern methods of protection of metals and alloys from corrosion.

Test № 1Section 2. Production of ferrous and nonferrous metals

Topic 2.1. Cast iron productionRaw materials for the production of cast The student should list the raw The student should list the raw

168

Contents of the topic Results Assessment criteriairon, their preparation for smelting. The metallurgical complex.The blast furnace: purpose and structure, and operating principle. Support equipment. Basic processes occurring in the blast furnace.Products of blast furnace production and their use. Techno-economic performance of the blast furnace and measures for improvement.Nonblast-furnace iron production.The main development directions of cast iron production.Safety requirements in blast furnace production. Measures to protect the environment.

materials for cast iron production, describe their preparation for smelting and the various methods of their production.The student should explain the structure and operation of the blast furnace, and reveal the essence of the blast furnace.

materials for cast iron production, and describe their preparation for smelting.The student should explain the structure and operation of the blast furnace, and reveal the essence of the blast furnace.The student should name the main development directions of the cast iron production.The student should set out the safety requirements in the blast furnace production, and measures to protect the environment.

Topic 2.2. Steel productionRaw materials for steel production. The basic and acidic lining. The essence of the redistribution of cast iron into steel. Modern methods of the steel production: oxygen-converter, open-hearth, and electric furnace.The structure and operation of smelting furnaces and their technical and economic indicators and comparisons.

The student should characterize steel production.

The student should list the raw materials for steel production. The student should reveal the essence of the process of redistribution of cast iron into steel.The student should describe current methods of steelmaking, and explain the structure and operation of modern steel-smelting

169

Contents of the topic Results Assessment criteriaCasting of steel and production of ingots.Development prospects of steel production.Safety requirements. Measures to protect the environment.

units.The student should name the main development directions of steel production.The student should set out the safety requirements steel production, and measures to protect the environment.

Topic 2.3. Production of non-ferrous metalsThe main non-ferrous metals and their properties.Types of copper ores and their enrichment. Production of copper using the pyrometallurgical method. Copper electrolysis, its scope.The raw material for aluminum production. The technological process of aluminum production, the scope.The main development directions of the production of non-ferrous metals and alloys.Measures to protect the environment in the production of ferrous and nonferrous metals.

The student should characterize production of non-ferrous metals.

The student should name the types of copper ores, raw materials for the production of aluminum.The student should describe the process of producing copper concentrate, blister and refined copper, and the aluminum production process.The student should name the main development directions of the production of non-ferrous metals and alloys.The student should set out measures for the protection of the environment in the production of ferrous and nonferrous metals.

Section 3. Methods of metal treatmentTopic 3.1. Foundry

The purpose and nature of the casting. The student should characterize The student shall reveal the

170

Contents of the topic Results Assessment criteriaCasting alloys. The casting alloy requirements. Melting units of foundries. The structure and operation of the cupola.Methods for producing castings. The model kit and its purpose. Molding and core materials, the requirements placed upon them.Technology of manual and machine molding. Molding tools and equipment. Drying of molds and cores. Fill in of the metal in forms, shake-out of castings out of flasks and dressing a casting.The spoilage in the foundry industry and measures to prevent it.Special methods for producing castings: permanent mold casting, injection molding, shell molding, centrifugal casting using investment (evaporating) castings. Advantages and disadvantages of different methods of producing castings.Safety requirements in the foundry industry. Measures to protect the environment.

foundry.The student should describe technologies of manual and machine molding, tools and devices for molding, drying of molds and cores.

essence of the foundry.The student shall describe the basic casting alloys, melting units, technology for the production of castings in single sand-clay forms, methods of making molds and cores, special methods of casting technology.The student shall set out the safety requirements in the foundry industry, measures to protect the environment.

Topic 3.2. Pressure treatmentPlastic deformation of metals. Factors affecting the plasticity of metals. The

The student should describe the process of metal pressure treatment.

The student shall explain the process of plastic deformation of

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Contents of the topic Results Assessment criteriaphenomena of hardening and recrystallization. Temperature conditions during pressure treatment. Burnout and overheating of metals. Heating equipment. Advantages of pressure metal treatment (PMT).Rolling: the essence, main types. Types of rolling mills. Mill products. Production of rebar periodic profile rods.Smith forging: the essence, operations. Forging tools and equipment. Application of forgings.Drawing: the essence, technology. Drawing equipment, drawing products.Pressing: the nature and equipment. Pressing products.Stamping: the nature, types, advantages. Technology for producing billets and products using the stamping method and their application.Safety requirements for machining. Measures to protect the environment.

metals, and describe the main heating equipment.The student shall reveal the essence of the main ways of pressure metal treatment (rolling, forging, drawing, pressing and stamping), and describe the resulting metal products, used equipment and tooling.The student shall set out safety requirements for machining, measures to protect the environment.

Topic 3.3. MachiningThe principle of interchangeability of parts and structures. Limits and hits. Limit systems. Types of hits, their purpose. Manufacturing accuracy and the surface roughness of the items, their

The student should characterize the essence of the metal machining process, limits and hits, accuracy of manufacture and surface roughness of parts, and describe their symbols.

The student should characterize the limits and hits, manufacturing accuracy, and surface roughness, and describe their symbols.The student should reveal the

172

Contents of the topic Results Assessment criteriasymbols. Accuracy degrees.Basic information about the technical dimensions.The cutting process. The main machining methods. Cutting tools. The main parts and elements of the cutter. Cutting modes.Classification of machining tools.Lathing. The main types of lathing operations. The structure of the lathe, its main parts. Automatic lathes and semi-automatic lathes.Drilling machine treatment. The main types of drilling operations.

Processing on milling machines. Types of milling operations. The structure and operating principle of the dividing head.The processing on planers. Planing process. Types of work performed on planers.The processing on grinding machines. The structure and operating principle of the grinding machine. The abrasive tool. The main types of grinding work.General information about the automation of cutting machine, about machines with computerized numerical

essence of the cutting process, describe the basic machining techniques, cutting tools and cutting modes.The student should distinguish the classification of cutting machines, structure and key parts of cutting machines.The student should explain the features of treatment on lathing, drilling, milling, planing and grinding machines, and describe the types of work performed on cutting machines.The student set out the safety requirements of and fire safety requirements in the machining process.

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Contents of the topic Results Assessment criteriacontrol (CNC), about automatic production lines and complex production automation.Safety requirements and fire safety requirements in the machining process.

Section 4. Welding and cutting metalsTopic 4.1. General information about the welding production. Physical fundamentals of welding. Power

supplies, accessories and tools for weldingStages of development of welding production: the invention of the electric arc, its use for welding by N.N. Benardos and N.G. Slavyanov.Welding, welded joints, soldering. Classification of welding by the physical (thermal, thermomechanical and mechanical classes), technical and technological features.The formation of the welded joint during fusion welding, pressure welding.Weldability of metals. Groups of technological steel weldability. The influence of alloying elements on the steel weldability. Weldability properties of cast iron, copper alloys, aluminum and its alloys.The main types of welded joints and weld seams. Legend of weld seams.Basic requirements for the power supply

The student should know the general data on welding production, its physical fundamentals, power supplies, accessories and tools for welding.

The student should name the stages of development of welding production.The student should reveal the essence of welding process, weld joins, and soldering, and explain the classification of the welding by physical, technical and technological features.The student should describe the basic steps of the production of a weld joint using fusion welding and pressure welding.The student should explain the metal weldability and determine steel weldability groups.The student should describe the basic types of welded joints and welded seams, welding methods.The student should set out the

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Contents of the topic Results Assessment criteriaof the electric welding arc. Classification of power supplies. Power supplies of the DC arc.Welding converters: types, structure and operating principle.Welding rectifiers: structure and operating principle. The advantages and disadvantages compared with the converters.Power supplies of the AC arc. Welding transformers: types, structure and operating principle. Methods to control current and voltage in the welding machines.Modern welding equipment.Welding accessories and tools. Safety requirements when connecting power supplies to an electrical network and in the welding process.

basic requirements for the power supplies of the electric welding arc and classification of power supplies.The student should explain features, structure and operating principle of welding converters, welding rectifiers, welding transformers.The student should describe the welding accessories and tools.The student should set out safety requirements when connecting power supplies to an electrical network and in the welding process.

Topic 4.2. Manual arc weldingStructure and properties of the electrical welding arc. Types of welding arcs. Thermal properties of the welding arc, the ionization degree of the arc. The process of ignition and burning of the welding arc.Metallurgical processes in fusion welding. The crystallization of the metal

The student should characterize the classification of welding and describe manual arc welding.

The student should describe the structure and properties of the electrical welding arc, types of welding arcs, welding arc ignition process.The student should communicate the classification and describe methods for arc welding.

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Contents of the topic Results Assessment criteriain the weld pool: primary and secondary. The structure of the weld seam.Classification and methods of arc welding. Selecting of a welding mode. Welding station equipment. Welding materials. Selection of electrodes.Manual arc welding technology. Techniques for different welding seams.Safety requirements for manual arc welding.

The student should explain the features and selection of welding electrodes, and describe welding materials, the equipment of the welding station, technology of the manual arc welding and techniques for different welding seams.The student should set out the safety requirements for manual arc welding.

Practical work 3The study of the structure and operation of welding machines for manual arc welding.

The student should study the structure and operation of welding machines for manual arc welding.

The student should analyze the structure and operation of welding machines for manual arc welding.

Topic 4.3. Automatic and mechanized submerged arc welding. Gas-shielded weldingThe essence of the submerged arc welding, its advantages. Welding flux: types, composition, and scope. Equipment for the submerged arc welding: stationary and mobile. Automatic welding heads and welding tractors. Hose semi-automatic machines.Submerged arc welding technology: single-sided, double-sided, butt welding, welding of T-joints and lap joints. Electroslag welding, welding of fixtures by the bath method.

The student should characterize automatic and mechanized submerged arc welding, and gas-shielded welding.

The student should reveal the essence of submerged-arc welding, and describe the types of welding fluxes, operating modes and submerged-arc welding equipment.The student should explain the submerged-arc welding technology.The student should communicate the safety requirements for submerged-arc welding.

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Contents of the topic Results Assessment criteriaSafety requirements in the submerged arc welding.The essence of the gas-shielded welding, its advantages. Manual, semiautomatic and automatic gas-shielded welding. Electrodes, welding wire, shielding gases.Equipment for gas-shielded welding. The argon-atmosphere welding and carbon-dioxide-atmosphere welding, their methods, scope. Technique for making seams.Safety requirements for the gas-shielded welding.

The student should reveal the essence of the gas-shielded welding, and describe the types of shielding gases, equipment and modes of the gas-shielded welding.The student should explain the technique for argon-atmosphere welding and carbon-dioxide-atmosphere welding.The student should set out the safety requirements for the gas-shielded welding.

Topic 4.4. Arc cuttingThe arc cutting methods. Consumable electrode cutting. Electrodes for the arc cutting. The oxy-arc cutting.Non-consumable electrode cutting. The air-arc cutting. Cutting equipment and tools. The plasma-arc cutting. Plasma cutters and other cutting installations.Safety requirements for cutting metals.

The student should characterize the types and methods of the arc cutting, composition and electrode classification, arc-cutting modes, cutting equipment and tools.

The student should describe the types and methods of the arc cutting, composition and electrode classification, arc-cutting modes, cutting equipment and tools.The student should explain the arc cutting technology.The student should set out safety requirements for cutting metals.

Topic 4.5. Contact welding. Gas welding and cuttingThe essence and contact welding methods. Hard or soft welding modes.Upset butt resistance welding

The student should characterize the essence of contact welding; describe the main methods and modes. The

The student should reveal the essence of the contact welding, and describe the basic methods

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Contents of the topic Results Assessment criteria(continuous and intermittent melting).Spot contact welding.Seam contact welding.Machines for butt contact welding, spot contact welding, seam contact welding.Safety requirements when working with contact welding machines.Gas welding: the nature, scope, advantages and disadvantages.Equipment for autogenous welding positions. Combustible gases used for gas welding. The structure of the oxyacetylene flame, its types and purpose.Gas welding technology. Gas cutting technology.Safety requirements performing gas welding and flame cutting.

student should describe the essence of gas welding, types of flammable gases, equipment for autogenous welding positions.

and modes.The student should explain features of butt, spot and seam contact welding, and describe the equipment for butt, spot and seam contact welding.The student should explain the technology for butt, spot and seam contact welding.The student should set out safety requirements when working with contact welding machines.The student should reveal the essence of the gas welding and describe the types of flammable gases, equipment for autogenous welding positions.The student should explain the technology of gas welding and gas cutting.The student should communicate the safety requirements of gas-welding works and flame cutting.

Practical work 4The study of the structure and operating principle of the spot welding machine in the manufacture of frames and grids of reinforcement.

The student should study the structure and operating principle of the spot welding machine in the manufacture of frames and grids of

The student should analyze the structure and operating principle of the spot welding machine in the manufacture of frames and grids

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Contents of the topic Results Assessment criteriareinforcement. of reinforcement.

Practical work 5The study of the technology for the butt, spot and seam contact welding.

The student should study the technology for the butt, spot and seam contact welding.

The student should analyze the technology for the butt, spot and seam contact welding.

Practical work 6The study of the technology for the gas welding and gas cutting.

The student should study the technology for the gas welding and gas cutting.

The student should analyze technology for the gas welding and gas cutting.

Test № 2Topic 4.6. Welding defects and its quality control

Defects in weld seams. Types of the control over welded joints: external examination, metallographic examination, chemical analysis, X-raying, magnetic inspection, ultrasonic testing, testing the density of weld seams (by kerosene, compressed air, vacuum apparatus, ammonia etc.).

The student should describe the defects in weld seams and its quality control.

The student should describe defects in weld seams, types of welded joints.

Practical work 7Carrying out the quality control of weld seams by the ultrasonic (magnetic) method.

The student should carry out the quality control of weld seams by the ultrasonic (magnetic) method.

The student should carry out the quality control of weld seams by the ultrasonic (magnetic) method.

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GuidelinesTo implement the syllabus on the academic discipline Metal

Technology and Welding, we recommend the following teaching forms: lectures, seminars, excursions, laboratory and practical work.



When presenting the educational material according to the syllabus, it is required to observe the unity of technical terminology and symbols for technical variables according to existing standards and Unified system of technological documentation (ESTD).

In order to ensure an adequate level of professional training when studying the academic discipline, it is recommended to use technical training aids (computer, multimedia projector, etc.) and demonstration training aids (charts, posters, drawings, and models).

To consolidate the theoretical material and to form students' skills and abilities, the syllabus provides for carrying out practical and laboratory work. Before lab classes, students should be familiar with the labor safety regulations. The teacher based on the learning objectives and content of the training material shall determine the form of the practical and laboratory work by the topics.





levels of complexity (minimum, medium and hard).Upon studying the academic discipline, the student shouldknow the following:- A set of productions combining iron and steel industry;- The main development directions of the production of steel, cast

iron, nonferrous metals and alloys;- The main directions and prospects of development of fusion and

pressure welding;- Atomic crystal structure of metals;

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- The composition and structure of metals and alloys, their classification;

- Physical, chemical, mechanical and technological properties of metals and alloys;

- Methods for determining the basic mechanical properties of metals;- Principles of building phase alloy diagrams;- Types and purpose of the structural and tool steel, including

reinforcing-bar steel;- Classification and branding of steel, cast iron and non-ferrous

alloys based on aluminum and copper;- The scope of the ferrous and non-ferrous metals and alloys;- The basis of production technology of steel, cast iron and non-

ferrous metals;- Methods of reinforcing steel processing: thermal and chemical-

thermal, surface hardening;- Basic methods to protect metals from corrosion;- Methods of metal casting (sand and special molds), pressure metal

treatment, cutting;- Theoretical foundations of welding and metal cutting;- The sequence of welding works;- Welding works in the construction and installation work;- Technology of arc welding, contact welding;- Structure and operating principle of: welding machines for manual

arc welding, the spot welding machine;be able to: - Determine the hardness and toughness of metals;- Build cooling curves of iron-carbon alloys;- Determine the microstructure of carbon steel, cast iron, and alloy

steel based on the results of microscopic analysis;- Interpret branding of steel, cast iron, non-ferrous metals and alloys;- Determine the kind of carbon steel and cast iron by their structure;- Assign modes and perform basic operations of heat treatment of

carbon steel;- Interpret the legend of welded joints in the drawings;

- Perform the weld seam quality control using one of the physical methods.

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HEAT ENGINEERING

The purpose of teaching of the academic discipline is the study of the theoretical fundamentals of heat engineering, thermal processes and thermal equipment for the production of construction products and designs.


Section, topic

Number ofhours

total

including those of practical

workIntroduction 11. Theoretical basics of heating engineering 22. The thermodynamic processes of perfect gases 4 23. Fundamentals of heat transfer 6 44. Fundamentals of hydro- and aerodynamics 4 25. Thermal installations of special purpose 6 46. Firing installations 4 27. Heat exchangers 4 48. General information about heating devices 7 6Test 19. Furnace heaters in mechanical-repair departments of metallurgical plants 9 8

Total 48 32

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CONTENTS OF THE DISCIPLINEContents of the section, topic Results Assessment criteria

IntroductionThe purpose and objectives of the academic discipline, its relationship with other academic disciplines. The significance and types of thermal processes in the production of materials and products.Basic indicators of thermal installations. Ways of energy saving in the production of materials and products.

The student should express a general judgment about the goals and objectives of the academic discipline and its relationship with other academic disciplines; the role and types of thermal processes in the production of materials and products.

The student should express a general judgment about the goals and objectives of the academic discipline and its relationship with other academic disciplines; the role and types of thermal processes in the production of materials and products.The student should name the main indicators of the performance of thermal installations, and express a general judgment about possible ways of reducing energy consumption in the production of materials and products.

Topic 1. Theoretical basics of heating engineeringImperfect and perfect gases, the working fluid. The main working fluid status parameters (temperature, pressure, specific volume), their units.

The student should characterize theoretical basics of heating engineering.

The student should express a general judgment about imperfect and perfect gases, the working fluid, explain the physical nature of the main working fluid status parameters, and describe their units.

The combined gas law. The equation of state of an ideal gas. The gas constant and its physical meaning. Universal gas constant. Avogadro's law and its consequences.

The student should formulate basic gas laws, write down their mathematical expression, reveal the physical meaning of the gas constant, and explain the designation and unit of measure.

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Contents of the section, topic Results Assessment criteriaSpecific heat capacity. Types of heat capacity and the heat capacity dependence on temperature. True and average heat capacity. Heat capacity in operations at a constant pressure volume; the relationship between them. Determination of the amount of heat.

The student should formulate the concept of heat capacity and its types, and explain the features of the heat capacity dependence on temperature.The student should set out the algorithm for calculating the amount of heat using heat capacity.

Topic 2. The thermodynamic processes of perfect gasesBasic thermodynamic processes of change of a perfect gas state: isochoric, isobaric, isothermal, adiabatic. The equations of these processes, a graphic image in p-v and T-s coordinates, the relationship between the main parameters, determination of the amount of the emitted (spent) heat or work done by the gas.Thermodynamic process. Graphical representation of the process in p-v coordinates. The work done by the gas during its expansion and contraction. The internal energy of the working fluid. The first law of thermodynamics, its physical meaning and mathematical expression. The concept of entropy and enthalpy of the working fluid.

The student should describe the basic thermodynamic processes of change of a perfect gas state: isochoric, isobaric, isothermal, adiabatic.

The student should describe special cases of thermodynamic processes; develop equations of these processes, a graphic image in p-v and T-s coordinates, formulate the relationship between the main parameters, determination of the amount of the emitted (spent) heat or work done by the gas.The student should express an overall judgment on the thermodynamic process, and explain the concept of internal energy of the working fluid, enthalpy and entropy of the working fluid.The student should explain the algorithm for determining the value of work done by the gas, formulate the first law of thermodynamics, and explain its physical meaning.

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Contents of the section, topic Results Assessment criteriaPractical work 1

Determination of parameters of gases and mixtures thereof in various thermodynamic processes.

The student should define parameters of gases and mixtures thereof in various thermodynamic processes.

The student should calculate parameters of gases and mixtures thereof in various thermodynamic processes.

Topic 3. Fundamentals of heat transferCircular processes (cycles) of thermal machines. Thermal efficiency of the cyclic process. Carnot’s cycle of the heat engine. The essence of the second law of thermodynamics.

The student should describe the fundamentals of heat transfer.

The student should describe the nature of circular processes of heat engines.The student should explain the formula of the thermal efficiency of the circular process, the thermal efficiency of Carnot’s cycle. The student should explain the essence of the second law of thermodynamics.

The water vapor, the scope of application, methods of preparation. States of the water vapor. Parameters of the water vapor. Image of vaporization in T-s and h-s coordinates.Determination of the parameters of the water and water vapor by means of Vukalovic’s tables. Determination of the parameters of the water vapor by the h-s diagram.

The student should name the methods of preparation and application of vapor.The student should describe the state of water vapor, symbols of the parameters of water vapor and water, and explain the algorithm for determining the parameters of water and water vapor using Vukalovic’s tables and h-s diagram.

The humid air. Saturated and unsaturated humid air. Parameters of the humid air: absolute and relative humidity, the moisture content,

The student should reveal the notion of humid air, and describe its parameters.The student should explain the

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Contents of the section, topic Results Assessment criteriaenthalpy. Dew point. h-d diagram of the humid air and using it to build and calculate drying processes.

methodology for calculating the heat carrier in the dryer using the h-d diagram of humid air.

The role of heat transfer in different processes.Methods of heat transfer (heat conduction, convection, radiation).Determination of the heat flux during heat transfer of heat conduction through the flat and cylindrical single-layer and multi-layer walls. Calculation of the power of heat flow in the convective heat transfer. The heat transfer coefficient. The calculation of radiation heat transfer. Coefficient of radiation. Sophisticated heat. Heat transfer through the flat and cylindrical single-layer and multi-layer walls. Thermal performance of building materials.

The student should express an overall judgment on the role of heat transfer in the thermal processing units.The student should explain the physical meaning of different types of heat transfer.The student should set out the algorithm for calculating the heat flux for different types of heat transfer.The student should define the scope of building materials according to their thermal properties.

Practical work 2Defining the parameters of the water vapor by means of Vukalovic’ tables and h-s diagram.

The student should describe the parameters of the water vapor using Vukalovic’s tables and h-s diagram.

The student should identify the parameters of the water vapor using Vukalovic’s tables and h-s diagram.

Practical work 3Calculation of heat transfer through the walls of the buildings.

Calculation of heat transfer through the walls of the buildings.

The student should produce the calculation of heat transfer through the walls of the buildings.

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Contents of the section, topic Results Assessment criteria

Topic 4. Fundamentals of hydro- and aerodynamicsBasic concepts and definitions of hydro- and aerodynamics: the equivalent diameter, rate, consumption. The equation of flow uniformity. Laminar and turbulent flow modes.Types of pressure: static, dynamic, geometric, lost to overcome resistance; their physical meaning and mathematical expression.Bernoulli's equation for perfect and imperfect gases. Types of aerodynamic drags.Forced devices: chimneys and fans. The principle of their action, the main characteristics.

The student should characterize the basic concepts and definitions of hydro- and aerodynamics. The student should explain the physical meaning and mathematical expression of the equation of flow uniformity, Bernoulli’s equation.

The student should formulate the concept of speed, flow, pressure and its variants.The student should explain the physical meaning and mathematical expression of the equation of flow uniformity, Bernoulli’s equation.The student should describe the types of aerodynamic drags.The student should explain the construction and operation of chimneys and fans, and communicate their characteristics.

Practical work 4Determination of the basic quantities characterizing the hydro aerodynamic flow.

The student should determine the basic quantities characterizing the hydro aerodynamic flow.

The student should produce calculation of quantities characterizing the hydro aerodynamic flow.

Topic 5. Thermal installations of special purposeThe concept of fuel. The main directions of development of the fuel industry of the Republic of Kazakhstan.Classification of fuels. The elemental composition of the fuel. The heat of fuel

The student should express a general judgment about the fuel, its types, and main directions of development of the fuel industry in the Republic of Kazakhstan.

The student should express a general judgment about the fuel, its types, and main directions of development of the fuel industry in the Republic of Kazakhstan.

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Contents of the section, topic Results Assessment criteriacombustion and its calculation. Conventional fuel. Brief description of the main types of fuel.The essence of the fuel combustion process. The equations of chemical reactions of fuel combustion. Complete and incomplete combustion. Air flow for fuel combustion. Excess air ratio. The quantitative composition of the fuel combustion products. The temperature of fuel combustion.Classification of electric power stations.The structure and operating principle of steam turbines and gas turbine plants. The operational principle of heat and power plants, thermal electric plants, nuclear power plants.Boiler plants, their purpose. Classification of boiler plants. Basic indicators of boiler plants.Elements of the boiler unit and their purpose. Schematic diagram of the boiler plant.The main directions in the boiler development. The structure and operational principle of fire-tube and water-tube boilers.

The student should describe the structure, basic properties, characteristics and use of different types of fuel used in the building materials industry.

The student should describe the structure, basic properties, characteristics and use of different types of fuel used in the building materials industry.The student should set out the algorithm for calculating fuel-combustion process.The student should express an overall judgment on the thermal power plants, about their purpose and types.The student should explain the structure, operation of steam turbines, gas turbine plants, and the concepts of the operation of heat and power plants, thermal electric plants, nuclear power plants.The student should explain an overall judgment on the purpose of boiler plants, their types.The student should explain the structure and operational principle of the boiler plant. It describes the device and operation of fire-tube and water-tube boilers, and formulate the directions of improvement of boilers.

Practical work 5

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Contents of the section, topic Results Assessment criteriaCalculation of the combustion process of solid and liquid fuel.

Calculation of the combustion process of solid and liquid fuel.

The student should calculate combustion processes of solid and liquid fuel.

Practical work 6Calculation of the combustion process of gaseous fuel.

Calculation of the combustion process of gaseous fuel.

The student should calculate the combustion process of gaseous fuel.

Topic 6. Firing installationsFeatures of the combustion of solid, liquid and gaseous fuels. Designation and classification of firing installations.Firing installations for solid, liquid and gaseous fuels. Typical designs of layered furnaces: semi-mechanical and mechanical furnaces with manual service.Chamber furnaces. Burners and nozzles for the supply of gaseous and liquid fuels in furnace chambers.

The student should explain the structure and function of layer burners, burners, and nozzles.The student should name the stages of combustion of solid, liquid and gaseous fuels.

The student should name the stages of combustion of solid, liquid and gaseous fuels, and express an overall judgment on the purpose of furnaces and their types.The student should explain the structure and function of layer burners, burners, and nozzles.

Practical work 7Calculation of the geometric dimensions of the furnace and determination of its efficiency.

Calculation of the geometric dimensions of the furnace and determination of its efficiency.

The student should produce the calculation of the geometric dimensions of the furnace and determine its efficiency.

Topic 7. Heat exchangersPractical work 8

The study of the structure and operation of standard heat exchangers (heaters, recuperative heat exchangers, regenerators, economizers, superheaters). Method of calculation of

The student should describe the methodology of calculation of heat exchangers, theirs structure and operating principle.

The student should analyze the structure, the operating principle of standard heat exchangers, the method of their calculation.

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Contents of the section, topic Results Assessment criteriathe heat exchanger.

Practical work 9Calculation of the heating surface of the heat exchanger.

Calculation of the heating surface of the heat exchanger.

The student should produce the calculation of the heating surface of the heat exchanger.

Topic 8. General information about heating devicesIndustrial furnaces, purpose, classification. Metallurgical furnaces for production of metals and heating furnaces. Mechanical facilities furnaces. Boiler plants, their classification, and the basic structure. Heat exchange equipment, its types, and the basic structure. Heating devices and appliances.

The student should explain the purpose and classification of industrial furnaces, describe the structure and operational principle of metallurgical furnaces.

The student should explain the purpose and classification of industrial furnaces, describe the structure and operational principle of metallurgical furnaces.The student should express features of boiler plants and their classification.The student should explain the essence of heating devices and appliances.

Practical work 10Thermal calculations for the preparation of an industrial furnace.Calculation of the amount of heat required for melting the metal with different carbon content.

Thermal calculations for the preparation of an industrial furnace.

The student should produce the calculation of the amount of heat required for melting the metal with different carbon content.

Practical work 11Thermal calculations for the preparation of a metallurgical furnace.Calculation of the amount of heat required for melting the metal with different carbon content.

Thermal calculations for the preparation of a metallurgical furnace.Calculation of the amount of heat required for melting the metal with different carbon content.

The student should produce the calculation of the amount of heat required for melting the metal with different carbon content.

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Contents of the section, topic Results Assessment criteriaPractical work 12

Compiling a heat balance table and determination of the specific consumption of steam, heat, electricity.

Compiling a heat balance table and determination of the specific consumption of steam, heat, electricity.

The student should compile a heat balance table and determination of the specific consumption of steam, heat, electricity.

TestTopic 9. Furnace heaters in mechanical-repair departments of metallurgical plants

Melting furnaces. Purpose, operating principles, design fundamentals, technology, parameters and indicators of cupola furnaces, electric arc and induction furnaces. Heating and heat treatment furnaces. Purpose, operating principle, design fundamentals, technology, parameters and indicators of fuel and electric furnaces.

The student should explain the operating principles, design fundamentals, technology, parameters and indicators of cupola furnaces, electric arc and induction furnaces.

The student should explain the operating principles, design fundamentals, technology, parameters and indicators of cupola furnaces, electric arc and induction furnaces, describe the operating principle, design fundamentals, technology, parameters and indicators of fuel and electric furnaces.

Practical work 13Study of melting furnaces. Their operating principle. Safety requirements in the operation for the furnace. Measures to protect the environment.

The student should analyze melting furnaces and their operating principles.

The student should analyze the types, structure, operating principle of the melting furnace.The student should set out safety requirements for the operation, measures to protect the environment.

Practical work 14Study of heating and heat treatment furnaces structure, their operating principle. Safety requirements for the operation of the furnace. Measures to

The student should study heating and heat treatment furnaces structure, their operating principle.

The student should analyze the types, structure, operating principle of heating and heat treatment furnaces.The student should set out safety

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Contents of the section, topic Results Assessment criteriaprotect the environment. requirements for the operation,

measures to protect the environment.

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GuidelinesTo implement the syllabus on the academic discipline Heating

Engineering, we recommend the following teaching forms: lectures, seminars, excursions, and laboratory work.



In presenting the training material you should take into account the latest achievements of science and technology, pay special attention to saving material and energy resources, safety at work and environmental protection. During the training, it is required to use teaching and visual aids.





levels of complexity (minimum, medium and hard).Studying the academic discipline, the student shouldknow:- The basic laws of heat transfer processes, movement of liquids and

gases in relation to process units;- The basic laws of chemical and physico-chemical processes, mass

transfer processes in relation to technological processes, units and metallurgic equipment;

- Major groups and classes of modern materials, their properties and scope, choice principles.

- Computer graphics methods;- Analytical methods for processes and their impact on the quality of

the products obtained.be able to: - Build drawings of parts and elements of constructions;- Calculate and analyze processes of internal and external heat

exchange in devices of various technological purpose, choose rational temperature and thermal conditions for metallurgical equipment;

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- Apply the standard approaches to ensure health and safety and environmental friendliness;

- Apply the methods of processing and analysis of experimental data, organizing scientific and technical information;

- Take the technological solutions, which allow using non-waste and resource-saving technologies in metallurgy.

- Analyze, calculate and select the metallurgical equipment of various technological purpose;

- Work with modern software for preparation of design documentation;

- Analyze the technical and economic indicators of heating equipment;

- Perform heat-engineering calculations of thermal installations;- Determine the cost of heat, coolant and fuel.

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RECORDS MANAGEMENT IN STATE LANGUAGE

The purpose of teaching of the academic discipline is development of professional competence in the field of documentation and organization of work with the organizational and administrative documentation.

The academic discipline Records Keeping in the State Language is a part of the cycle of general professional disciplines of the syllabus and is compulsory to study at training in all specialties of secondary special education.


Section, topic

Number of hours

total

includingthose of practical

workIntroduction 1Section 1. Management activities documentation

15 4

1.1. Types and significance of documents 11.2. State standards for the execution of

documents6

1.3. Rules for presentation and arrangement of document details

8 4

Section 2. Features of the preparation and execution of organizational and administrative documents

36 24

2.1. Organizational and administrative documents

12 8

2.2. Information and reference documents 16 102.3. Documentation of work 8 6Section 3. Workflow management 24 123.1. The structure and scope of the workflow 7 4Test 13.2. File register. Compilation of files 8 43.3. Document value expertise. Transferring files to the archive of the organization

8 4

Total 76 40

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IntroductionThe goals, objectives and contents of the academic discipline, its relationship with other academic disciplines.Basic regulations governing the organization of the record keeping in the Republic of Kazakhstan

The student should describe the goals and objectives of the academic discipline, the basic regulations governing the organization of the record keeping in the Republic of Kazakhstan.

The student should name the goals and objectives of the academic discipline, the basic regulations governing the organization of the record keeping in the Republic of Kazakhstan.

Section 1. Management activities documentationTopic 1.1. Types and significance of documents

The concepts of "documentation", "information", "document", "documented information", "informatization." The document as a media. The role of information and documents in human society. The information value of the document.Characteristics of the document as a system object.Document functions: information, communication, reclamation, administrative, legal, etc.)The concept of classification of documents. The terms "original" and "copy". The criteria for the authenticity of an electronic document and documents on traditional (paper) media. Types of copies, their application.The procedure for the execution of the document.

The student should characterize the types of documents, reveal their meaning, and classify management documents.

The student should describe the types of documents, reveal their meaning, and classify management documents.

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Contents of the topic Results Assessment criteriaTopic 1.2. State standards for the execution of documents

The unification and standardization of documents.Systems of organizational and administrative documentation.Requirements for the execution of documents.The layout for the organizational and administrative documentation. Document forms.

The student should describe the state standards for the execution of documents.

The student should express a general judgment on unification and standardization of documents.The student should explain the purpose of the layout.The student should set out requirements for the execution of document forms.

Topic 1.3. Rules for presentation and arrangement of document detailsTypes of details: permanent and variable, mandatory and optional, giving the legally binding to the document. Requirements for the text of documents.

The student should describe the rules for presentation of document details.

The student should describe the composition of the details of the document, their types, purpose and location on the document, set out the basic requirements for the text of documents.

Practical work 1Development of layouts of the general form and the form of letters of a particular organization.

The student should develop layouts of the general form and the form of letters of a particular organization.

The student should develop layouts of the general form and the form of letters of a particular organization.

Section 2. Features of the preparation and execution of organizational and administrative documentsTopic 2.1. Organizational and administrative documents

General characteristics and structure of documents belonging to organizational and administrative groups. Details, content, the procedure for the execution.

The student should set out the composition of organizational and administrative documents.

The student should set out the composition of organizational and administrative documents, describe the details, content and the procedure for the execution.

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Preparation and execution of the job description.

The student should prepare and draw up a job description.

The student should prepare and draw up a job description.

Practical work 3Preparation and execution of orders on core activities.

The student should prepare and draw up orders for core activities.

The student should prepare and draw up orders for core activities.

Topic 2.2. Information and reference documentsTypes of information and reference documents: letter of information, report and an explanatory note, certificate, minutes. Requirements for their preparation and execution.The management letter: types, execution features.

The student should describe the types of information and reference documents.

The student should describe the types of information and reference documents, set out the requirements for their preparation and execution, and explain features of execution of official letters.

Practical work 4Preparation and execution of the management letter.

The student should prepare and draw up a management letter.

The student should prepare and draw up a management letter.

Practical work 5Preparation and execution of the letter of information, report and explanatory note.

The student should prepare and draw up a letter of information, report and explanatory note.

The student should prepare and draw up a letter of information, report and explanatory note.

Practical work 6Preparation and execution of the certificate. The student should prepare and

draw up a certificate.The student should prepare and draw up a certificate.

Practical work 7Preparation and execution of the minutes of a complete and short form.

The student should prepare and draw up a minutes of a complete and short form.

The student should prepare and draw up a minutes of a complete and short form.

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Contents of the topic Results Assessment criteriaTopic 2.3. Documentation of work

Classification of the personnel documentation. Documentation of the movement of personnel (employment, transfer, dismissal). Execution of personnel orders, maintenance of work-record books, personal cards, the composition of the personal file.Particulars of official personal (registered) documents (reference, autobiography, power of attorney, receipts, resumes, applications).

The student should describe working documents.

The student should describe documents on personnel matters, and explain features of execution of official personal documents.

Practical work 8Preparation and execution of personnel orders. The student should prepare and

draw up a personnel order.The student should prepare and draw up a personnel order.

Section 3. Workflow managementTopic 3.1. The structure and scope of the workflow

Workflow: significance, volume, structure, main stages. Workflow management: basic principles. Сomputerization of document management.Requirements for admission, registration, execution of internal and external documents. Forward document registry. Indexation of the internal document. Classification of document deadlines. Document execution control as an essential management function and an important part of document management. Features of the control for execution of administrative documents, minutes of board

The student should express an overall judgment on the workflow, its significance, scope, structure and main stages.

The student should express an overall judgment on the workflow, its significance, scope, structure and main stages.The student should set out the basic principles of the workflow organization, requirements for admission, registration, and execution of external and internal documents, maintenance of the forward document register.The student should describe the procedure for assigning an index to an internal document, and explain the

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Contents of the topic Results Assessment criteriameetings, meetings. classification of document deadlines,

and the features of the control of execution of documents.

Practical work 9Registration of incoming documents in register books and in registration and control cards.

The student should perform registration of incoming documents in register books and registration and control cards.

The student should perform registration of incoming documents in register books and registration and control cards.

Practical work 10Registration of outgoing and internal documents in register books and in registration and control cards.

The student should perform registration outgoing and internal documents in register books and in registration and control cards.

The student should perform registration outgoing and internal documents in register books and in registration and control cards.

TestTopic 3.2. File register. Compilation of files

The role and importance of the file register. Types of file registers: standard, exemplary, organization’s files; their purpose, differences. The procedure and timing of preparation, coordination and approval of file registers. Basic requirements for the execution of files. The order of documents in the file.

The student should set out the procedure and timing of preparation, coordination and approval of file registers, and also the requirements for the execution of files, the order of documents in the file.

The student should reveal the role and importance of file registers, describe their types, set out the procedure and timing of preparation, coordination and approval of file registers.The student should set out the requirements for the execution of files, the order of documents in the file.

Practical work 11The use of technical means when working with documents.

The student should use technical means when working with documents.

The student should use technical means when working with documents.

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Contents of the topic Results Assessment criteriaTopic 3.3. Document value expertise. Transferring files to the archive of the organization

The significance and procedure for organization of the document value expertise.The procedure for online storage of documents. Preparation of files for transfer to the archive.

The student should set out the procedure for online storage of documents, and preparation of files for transfer to the archive.

The student should express a general judgment about the document value expertise.The student should set out the procedure for online storage of documents, and preparation of files for transfer to the archive.

Practical work 12Preparation and execution of files. The student should prepare and

draw up files.The student should prepare and draw up files.

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GuidelinesTo implement the syllabus on the academic discipline Records Keeping in

the State Language, we recommend the following teaching forms: lectures, seminars, excursions, and laboratory work.



The control of this academic discipline provides for interim assessment, basic forms of which are the following: passes and tests.


- Passes - 1.Educational organizations must develop competence-oriented tasks in the

test form and include them in the syllabus.Tests should be presented by sections and topics and have three basic levels

of complexity (minimum, medium and hard).Studying the academic discipline, the student shouldknow:- National standards and regulations for document management;- Record keeping system and the procedure for record keeping in the

organization;- Unified forms of primary records by the profile of professional activities;- Rules of preparation and execution of organizational and administrative

documents;- Requirements for the preparation and execution of the main types of

administrative documents;- General rules for the organization of incoming, outgoing and internal

documents;- The rules of the current document storage;- The procedure for the preparation of documentation for long term storage;

be able to:- Use regulations and methodological materials on record keeping and

archiving, the standard of the unified system of organizational and administrative documents;

- Draw up the details according to the layout;- Prepare and execute various types of organizational and administrative

documents and copies thereof;- Fill in primary accounting documents by the profile of the professional

activities;- Keep records of incoming and outgoing documents;- Prepare documentation for long term storage.

203

Ministry of Education and Science of the Republic of KazakhstanNon-commercial Joint stock Company «Holding «Kasipkor»

EDUCATIONAL PROGRAM

on the specialty: 1004000 – Foundry

Qualifications:

– 100402 2 – Mechanic-foundryman on machines and automatic lines*

– 100406 2 – Core maker of machine molding *– 100407 2 – Core maker of hand molding *– 100409 3 – Technician-metallurgist – ******** – Assistant Foundry Production Engineer

204

PART 1

Astana – 2015

205

CONTENT

Basics of computer technology in the industry 3

Theory and technology of foundry 13

Foundry alloys and melting 34

Design and technological basis for the production of moulds for manual molding

59

Economics, organisation and planning of production 64

Safety and health management 81

Automation of foundry 102

Design and technological basis for the production of moulds for machine molding

127

The systems of computer-aided design and simulation of foundry processes

133

Design of rigging 142

Automatic lines and systems 151

Automation of foundry production 164

List of training literature 173

List of training equipment 181

206

BASICS OF COMPUTER TECHNOLOGY IN THE INDUSTRY

The purpose of the study of the academic discipline is the formation of knowledge about the technology of computer processing of business information taking into account existing standards and means of protection, the use of a database management system to organize methods of creating, storing and processing information, about multimedia and networking technologies and their application in practice.


Section, topic

Number of hours

totalincluding those of

practical work

Introduction 1

Section 1. Subject area of activities and its information support

24 16

1.1. Information systems for professional use 2

1.2. Databases as business information systems 22 16

Section 2. Standards for business information processing

11 4

2.1. Standard systems of business information processing information technology. Standards for electronic documents

6 2

Test 1

2.2. Protection of business information 4 2

Section 3. Application software in professional activities

40 20

3.1. Use of the application software to perform complex calculations

14 8

3.2. Technology of creation and processing of textual information

10 4

207

Test 1

3.3. Technology of creation and processing of graphic and multimedia information

15 8

Total 76 40

208

CONTENTS OF THE DISCIPLINE


Introduction

Goals, objectives of the discipline " Basics of computer technology in the industry." The significance of the discipline when training professionals, connection with other subjects studied within the specialty.The essence of the computer processing of business information. Development trends of information technology.

The student should express an overall judgment on the goals, objectives and content of the discipline, the development trends of information technology.

The student should express an overall judgment on the goals, objectives and content of the discipline, the development trends of information technology.

Section 1. Subject area of activities and its information support

Topic 1.1. Information systems for professional use

Technology of business information computer processing, its types. Understanding information systems. The main types of information systems. The main objects, attributes, communications of information systems. Distributed Processing Technology. Types of software used in the systems. Help desk, search

The student should describe the purpose and capabilities of information systems, their types, the basic objects and attributes, distributed processing technology, the types of software used.

The student should describe the purpose and capabilities of information systems, their types, the basic objects and attributes, distributed processing technology, the types of software used.


engines.

Topic 1.2. Databases as business information systems

Purpose and use of database technology. Database models. Database management systems (DBMS). DBMS MS Access. Technology to create and modify database objects in MS Access. Tables as sources of information in a database. Forms as interface elements when working with databases. Queries and reports in the database.

The student should characterize the purpose of database technology, and describe its models, database management systems, technology to create and modify objects in DBMS MS Access.

The student should reveal the purpose of database technology, and describe its models, database management systems, technology to create and modify objects in DBMS MS Access.

Practical work 1

Analysis of information objects of the subject area of activities. Determining the structure of the database.

Analysis of information objects of the subject area of activities. Determining the structure of the database.

The student should develop and analyze the information and logical data model, and define the sources and structure of the database in the subject area of activities.

Practical work 2

Development of models of tables of reference, planning and accounting information. Defining a primary key.

The student should develop models of tables of reference, planning and accounting information, justify the choice of a key field,

The student should develop models of tables of reference, planning and accounting information, justify the choice

210


Entering and updating of data in the table.

and perform input and correction of data in the table.

of a key field, and perform input and correction of data in the table.

Practical work 3

Designing forms for entering, viewing and editing information.

The student should designs layouts of forms with various controls to perform easy entry, viewing and editing information.

The student should designs layouts of forms with various controls to perform easy entry, viewing and editing information.

Practical work 4

Construction of collection data queries in accordance with selection conditions. The development of single-table reports.

The student should designs layouts of collection data queries in accordance with the selection terms, and set the parameters in queries.

The student should designs layouts of collection data queries in accordance with the selection terms, set the parameters in queries, and develop single-table reports.

Practical work 5

Construction of multi-table collection data queries. The development of multi-table reports

The student should designs collection data queries based on several tables, queries previously created.

The student should designs collection data queries based on several tables, queries previously created, and develop multiple-reports.

Practical work 6

Development of summary tables and charts according to the information

The student should develop pivot tables and The student should develop pivot tables and charts based on the information system

211


system. charts based on the information system data. data.

Practical work 7

Arrangement of searching information on the Internet related to the subject area of the activities and its use. Changing the data in the system: updating, deleting, and adding.

The student should develop requests to modify data in the system.

The student should perform research on the Internet and use the information obtained, develop requests to modify data in the system.

Practical work 8

Creation of information and advertising messages to customers, arrangement of their distribution.

The student should create information and advertising messages to customers using data from the database and send them by e-mail.

The student should create information and advertising messages to customers using data from the database and send them by e-mail.

Section 2. Standards for business information processingTopic 2.1. Standard systems of business information processing information technology.

Standards for electronic documents

Regulations for information technologies, their purpose. General requirements for electronic documents. Life cycle planning, identification, authentication,

The student should set out the basic requirements for the design of electronic documents, describe the technology required to produce the desired pattern of the electronic document standards, the basic principles of

The student should explain the legal acts in the field of information technology, the general requirements for electronic documents, set out the basic requirements for the design of electronic documents,

212


establishment of protection and storage of electronic documents. Basic requirements for the design of electronic documents. Setting standards in the development of patterns of electronic documents. Standardization of computer networks.

standardization of computer networks. describe the technology required to produce the desired pattern of the electronic document standards, the basic principles of standardization of computer networks.

Practical work 9

Creating templates of business information using standards for electronic documents.

The student should develop templates of business information using standards for electronic documents.

The student should develop templates of business information using standards for electronic documents.

Topic 2.2. Protection of business information

Basic concepts of information security. Criteria for evaluation. Classification of information security threats. Methods and means of information protection. Legal security of information systems. Features of security in computer networks. The file system protection of business information from viruses,

The student should reveal the basic concepts of information security, the criteria for its evaluation, the classification of threats, methods and means of information protection.

The student should reveal the basic concepts of information security, the criteria for its evaluation, the classification of threats, methods and means of information protection.

213


unauthorized access. Organization of safe storage of business information.

Practical work 10

Securing documents from unauthorized access.

The student should arrange protection of documents from unauthorized access.

The student should arrange protection of documents of different applications from unauthorized access.

Test 1

Section 3. Application software in professional activities

Topic 3.1. Use of the application software to perform complex calculations

Classification of application software. The choice of application software for use in professional activities.

Features of MS Excel application when performing complex calculations.

The student should choose application software for use in professional activities.

The student should reveal the classification and the criteria for selecting application software for use in professional activities, explain the features of MS Excel application when performing complex calculations.

Practical work 11

Use of MS Excel application for performing calculations of the production program of the structural

The student should use MS Excel application for performing calculations of the production program of structural units of the organization.

The student should use MS Excel application for performing calculations of the production program of structural units

214


unit of the organization. of the organization

Practical work 12

Use of MS Excel application for operational records of the executed works (services).

The student should use MS Excel application for operational records of work performed (services), and analyze results obtained.

The student should use MS Excel application for operational records of work performed (services), and analyze results obtained.

Practical work 13

Use of MS Excel application for calculating the economic performance of the organization.

The student should use MS Excel application for calculating the economic performance of the organization.

The student should use MS Excel application for calculating the economic performance of the organization.

Practical work 14

Use of OLE-technology for exchanging data between MS Excel table processor and MS Word text editor.

The student should use OLE-technology for exchanging data between MS Excel table processor and MS Word text editor.

The student should use OLE-technology for exchanging data between applications.

Topic 3.2. Technology of creation and processing of textual information

Information cross-technology: optical character and speech recognition, automated and automatic text translation systems. MS Word

The student should reveal the content of information cross-technology, and describe MS Word features in the development of text

The student should reveal the content of information cross-technology, and describe MS Word features in the development of

215


features in the development of text documentation.

documents. text documents.

Practical work 15

Scanning and recognition of information. Formatting text in MS Word text editor. Styling the document, insertion of a table of contents.

The student should carry out formatting text in MS Word text editor.

The student should perform converting a paper document into an electronic document, and use the technology of formatting text documents and fragments thereof, styling, insertion of a table of contents.

Practical work 16

Development of compound documents.

The student should develop a compound document.

The student should develop a compound document using the technology of insertion of objects of other applications into the text document.

Test 2

Topic 3.3. Technology of creation and processing of graphic and multimedia information

Audio processing. Technologies of statistical images. Basic principles of digital video. Features of program-presentations to create advertising.

Development of web pages and web sites. The student should explain the technology of creation and processing of graphics and multimedia, design of presentations, web pages and web sites.

216


Development of web pages and web sites.

Practical work 17

Creating and editing graphics. The student should create and edit graphics. The student should create and edit graphics.

Practical work 18

Creating a bitmap and vector animated image.

The student should create a bitmap and vector animated image.

The student should create The student should create.

Practical work 19

Development of a presentation on marketing activities of the organization.

The student should develop presentations on marketing activities of the organization.

The student should develop presentations on marketing activities of the organization.

Practical work 20

Development of web pages for marketing activities.

The student should develop web pages for marketing activities.

The student should develop web pages for marketing activities.

217

Guidelines

To implement the syllabus on the academic discipline Fundamentals of Computer Technology in the Industry, we recommend the following teaching forms: lectures, seminars, and laboratory work.



In the presentation of the syllabus material, it is required to acquaint students with the latest developments in information technology in the country and abroad, with trends in the development of society informatization and formation of information culture.

It is required to use in the educational process personal computers connected in a local computer network, technical demonstration and training aids, computer tutorials, and electronic manuals.

For better assimilation of theoretical material by the students, they are required to perform practical work.



- Quizzes - 2;

- Passes - 1.

Educational organizations must develop competence-oriented tasks in the test form and include them in the syllabus.

Tests should be presented by sections and topics and have three basic levels of complexity (minimum, medium and hard).

As a result of the study of the academic discipline, the student should:know the following:

218

- Trends in the development of information technology;- Basics of building, development prospects of local and global computer

works, networking technology of information processing;- Ways of presenting and processing technology, storage and transmission of

information;- Classification of the PC software;- Numerical methods and principles of mathematical simulation of

application tasks;- Rules for using the hardware and software of the personal computer,

systems and networks;- The purpose and features of graphic and text editors, spreadsheets, and

database management systems for the creation of technical documentation applied in professional activities;

- Methods of information protection;be able to:- Use PC standard and application software;- Apply modern methods of computer-aided design;- Create electronic documents;- Search for information on the Internet, use e-mail, modern information

technology.

219

THEORY AND TECHNOLOGY OF FOUNDRY

The purpose of the study of the academic discipline is to develop in students a deep knowledge of the theory of the formation of the molding material properties, physical and chemical processes occurring in the mold from the beginning of its production before the end of the crystallization process of casting.


Section, topic

Number of hours

total

including

those for laboratory

work

1 2 3

Introduction 1

Section 1. Physical and chemical processes occurring during the formation of the properties of molding and core mixtures

5 2

1.1. Basics of creating the mold 1

1.2. Formation of the adhesive and cohesive bonds in the mold

4 2

Section 2. Fillers of molding and core mixtures 6 2

2.1. Classification of fillers of molding and core mixtures 3 1

2.2. High-, medium-, and low refractory fillers 3 1

Section 3. Binders 13 5

3.1. The classification and application of binders 3 1

3.2. Physical and chemical properties and application of modeling clay

4 2

3.3. Aqueous inorganic binders 4 2

220

1 2 3

3.4. Basics of synthesis of organic water binders, their variety and scope

2

Section 4. The classification and application of auxiliary materials

8 4

4.1. The main provisions of the surfactant theory of solutions

4 2

4.2. Hardeners and catalysts of binder systems 4 2

Section 5. Physical and chemical processes occurring during curing sand-resin mixes

4

5.1. The mechanisms of condensation and polymerization of thermosetting binders

2

5.2. The catalytic effect of salts on the curing process of sand-resin mixes

2

Section 6. Physical and chemical processes of hardening mixtures with inorganic binders

10 4

6.1. Liquid-glass mixtures 4 2

6.2. Phosphate mixtures 4 2

6.3. Polycondensation mixtures 2

Section 7. Basic theory of the formation of the properties of molding mixtures

8 2

7.1. Uniform molding mixtures 2

7.2. Facing (CFC) and filling (NSF) molding mixtures 4 2

7.3. Quality control of molding and core mixtures 2

Section 8. The mechanisms of defect formation in castings

16 8

8.1. Gas mode of the mold 4 2

8.2. The mechanisms of gas defect formation in castings 4 2

221

1 2 3

8.3. Types of burnings on castings and methods of its prevention. Nonstick materials and coatings.

4 2

8.4. The mechanisms of formation of scabs and embossments, and methods of dealing with them

4 2

Section 9. Modern methods of regenerating molding sands and mixtures

5 1

9.1. Preparation of mixture recycled for reuse 3 1

9.2. Physical and chemical processes occurring in the separation of the binder films on the surface of fillers of molding and core mixtures

2

Section 10. Technology of manual methods of making molds and cores

4

10.1. Molding tooling and instruments 2

10.2. Variety of hand molding in flasks 1

10.3. Schemes of hand molding sections 1

Section 11. The technology of mechanized and automated methods of shaping

8 2

11.1. Pressing methods of sealing molds 1

11.2. Dynamic methods of sealing molds 1

11.3. Combined methods of sealing molds 4 2

11.4. Basics of creating automatic molding lines 2

Section 12. The technology of manufacturing bars 5 2

12.1. Manual methods of manufacturing bars 1

12.2. Sending and sandblasting methods of manufacturing bars

3 2

12.3. Technology of coloring, drying, finishing and quality control of bars

1

222

1 2 3

Section 13. Fundamentals of designing of foundry equipment

3

13.1. Fundamentals of designing patterns and core boxes 1

Test 1

13.2. Methods for producing foundry patterns and core boxes

1

Total 96 32

Section 14. The technology of finishing operations of manufacturing castings

6 2

14.1. Filling molds 2

14.2. Technology of shakeout of castings from the mold, cores from castings

1

14.3. Stump, cleaning and quality control of castings 3 2

Section 15. Environmental aspects of casting manufacturing technology

4

15.1. Main types of pollutants produced during the mixture, manufacturing molds and cores

2

15.2. Gassing during pouring and cooling castings 1

15.3. Prospects of development of the foundry industry 1

Course design 30

Total 40 2

Overall 136 34

223



Introduction

The structure and content of the discipline “Theory and technology of foundry”. The purpose and objectives of the discipline. The history of the development of methods for molding. The casters and machine builders face challenges. The role of the discipline in the formation of professional knowledge, skills of students.

One express an overall judgment on the content of the subject “Theory and technology of foundry”

One expresses an overall judgment on the academic discipline “Theory and technology of foundry", on the role of discipline in shaping the professional knowledge and skills; on the challenges facing casters and mechanical engineers; the relationship with general educational and professional and special educational disciplines, the importance of the foundry industry for technical and economic development of the state.

Section 1. Physical and chemical processes occurring under forming properties of molding and core sands

Topic 1.1. Basics of creating foundry mold

The concept of the foundry molding. Their classification according to the methods of manufacture of castings. The main structural elements of the foundry molding and the methods of its manufacture.

One describes the basics of foundry mold manufacturing.

One explains the structure of the foundry mold and its functionality of all elements. One classifies foundry molds depending on the methods of manufacture of castings. One describes the basic methods of making foundry molds.

Topic 1.2. Formation of the adhesive-cohesive bonds in the foundry mold

224


Fundamentals of physical and chemical processes occurring at the interface of “a grain surface filler - a binder film” that determine the formation of the adhesion-cohesive bonds in molding and core sands. Principles of formation of the strength and other physical and mechanical properties of molding and core sands.

One formulates charts and explains the mechanisms of adhesion-cohesion processes occurring at the interface of “a grain surface filler – a binder filler”.

One draws up charts and explains the mechanisms of adhesion-cohesion processes occurring at the interface of “a grain surface filler – a binder film”. One describes the principles of strength and other physical and mechanical properties of molding and core sands.

Laboratory work No. 1

Determination of molding and core sands for compression, tensile, bending, surface hardness (friability).

One determines the strength of molding and core sands for compression, tension and bending and surface hardness (friability).

One introduces ways and methods for determining the strength properties of various kinds of molding and core sands. One defines the strength of the specimens for compression, tensile, bending, surface hardness (friability).

Section 2. Fillers for molding and core sands

Topic 2.1. Classification of fillers for molding and core sands

Classification characteristics of fillers according to fire resistance, thermal and strength characteristics. Their

One describes molding and core sands’ fillers.

One classifies fillers of molding sands. One explains their purpose and scope. One describes the physical and chemical and mechanical properties of

225


purpose and scope. Physical and chemical and mechanical properties of the refractory fillers and methods for their determination.

the refractory fillers and methods for their determination. One classifies the refractory molding fillers.


Determination of mass fraction of clay component, and uniformity coefficients and the average grain size, permeability, shape of grains of sand.

One describes the mass fractions of clay component, uniformity coefficients and average grain size, permeability and shape of sand grains.

One introduces research methods and techniques of molding sands.

One defines the mass fraction of clay component, and coefficient of uniformity and the average grain size, permeability and shape of the sand grains. One analyzes test results and determines the brand of foundry sand.

Topic 2.2. High-, medium-, and low-refractory fillers

The mineralogical and chemical composition of the refractory filler. The influence of impurities on the formation of adhesive bonds with constituents of binders.

One researches the composition of high-, medium and low-refractory fillers.

One describes mineralogical and chemical composition of the refractory filler. One explains impact of the origin of the refractory fillers on their physical and chemical properties. One explains the impact of impurities in the refractory fillers on formation of adhesive bonds with constituents of binders.


226


Experimental determination of the refractory quality of fillers.

One analyses the refractory quality of fillers.

One explains the methodology for determining the refractory quality of fillers. One analyzes the results of experiments and determines the refractory quality of fillers used in the foundry industry.

Section 3. Binding materials

Topic 3.1. The classification and application of binding materials

Classification of binding materials depending on their chemical nature, the presence of functional groups, physical and chemical curing processes, specific strength indicator. Purpose of binding materials and their applications.

One describes the classification and application of binding materials based on their chemical nature, the presence of functional groups, physical and chemical curing processes and specific strength indicator.

One classifies binding materials depending on their chemical nature, the presence of functional groups, physical and chemical curing processes, and specific strength indicator. One explains the purpose of binding materials and their applications.


Study of regularities of formation and experimental evaluation of the strength properties of binding materials.

One discovers the patterns of formation of binding materials and experimentally assesses their strength properties.

One classifies known binding materials based on the physical and chemical characteristics. One calculates specific strength of binding materials. One assesses the binding capacity of the binding materials.

Topic 3.2. Physical and chemical properties and applications of foundry loams

227


Classification of foundry loams. The difference between the crystal lattice structure of kaolinite and montmorillonite loam. The concept of colloidal and binding properties of these materials. Appointment of functional elements and mechanisms of the physical and mechanical properties of foundry loams.

One classifies foundry loams. One classifies foundry loams. One makes a block diagram of kaolinite and montmorillonite loams. One explains the functional elements and mechanisms of formation of physical and mechanical properties of foundry loams.


Experimental determination of the main characteristics of foundry loams.

One analyses the basic properties of foundry loams.

One analyzes the results of experiments and determines the strength, binding capacity and the thermal stability of bentonite loams.

Topic 3.3. Aqueous nonorganic binding materials

Basic information on aqueous binders. Their classification, chemical composition, methods of preparation and application.

One describes the features of aqueous binding materials base on their chemical composition and classifies them.

One explains features of aqueous binders, depending on their chemical composition. One classifies aqueous binders and illustrates methods for their preparation and application.


Experimental determination of the One discovers the impact the amount of One calculates the number of mixture components.

228


dependence of the tensile strength of the samples of soluble glass mixtures cured with carbon dioxide, on the amount of the binder in the mixture and curing time of the samples.

the binder in the mixture and curing time of samples have on samples’ tensile strength of soluble gas mixtures cured with carbon dioxide.

One prepares samples to determine the tensile strength. One analyzes the results of experiments and establishes a relationship of tensile strength of the samples of soluble glass mixtures cured with carbon dioxide, on the amount of the binder in the mixture and curing time of the samples.

Topic 3.4. Basics of synthesis of organic aqueous binding materials, their variety and scope

Basic concepts of organic aqueous binding material. Main terms as a “monomer”, a “polymer”, “polymerization”, “polycondensation” and etc. relating to the production and use of resinous binding material and their curing mechanisms of the mixtures of molding and core sands. The structure of the organic polymers and monomers.

One classifies organic aqueous binding materials, the synthesis of organic aqueous binding materials, their varieties and scope of application.

One classifies aqueous organic binding materials. One explains the structure of organic monomers and polymers. One makes condensation and polymerization reactions of organic binders. One refers to methods for producing resinous binding materials. One explains the mechanism of curing molding and core sands on the basis of water and resin binding materials.

Section 4. Classification and field of application of auxiliary materials

Topic 4.1. The main provisions of the theory of surface acting agents in solutions

Purpose and field of application of surface acting agents (SAA). Varieties

One expresses the basics of the SAA theory regarding solutions.

One explains the purpose and scope of the SAA. One presents the mechanism of the behavior of

229


of SAA, the mechanisms of their behavior in the compositions of binders and liquid self-hardening mixtures (LSM).

SAA in compositions of binders and LSM.


Research of influence of the type and amount of SAA on some technological properties of parting paints.

One describes the influence of the type and amount of SAA on some technological properties of parting paints.

One analyses the influence of the type and amount of SAA on some technological properties of parting paints.

Topic 4.2. Hardeners and catalysts of binder systems

Basic information about the difference between the concepts of “catalyst” and “curing agent”, the mechanisms of their action. Main curing agents and catalysts, the use in the compositions of molding and sands.

One describes curing agents of catalysts used in compositions of molding and core mixtures.

One explains the differences between the concepts of “catalyst” and “curing agents”. One explains the mechanisms of their action. One describes compositions of molding and core sands with hardeners and catalysts.

230



Choosing the best catalyst to produce castings.

One selects the best catalyst for castings. One selects the best catalyst for castings.

Section 5. Physical and chemical processes taking place during curing sand-resin mixtures

Topic 5.1. The mechanisms of condensation and polymerization of thermosetting binding materials

Classification of resin binders depending on the functional groups, their physical and chemical properties. Preparation of phenol-formaldehyde, urea and furan binder’s mechanisms of polymerization and polycondensation curing.

One describes the mechanisms of condensation and polymerization of thermosetting binding materials.

One classifies resin binders depending on the functional groups. One describes their physicochemical properties. One reveals the mechanism of polymerization and polycondensation curing.

Topic 5.2. The catalytic effect of salts on the curing process of sand-resin mixtures

Principles of manufacturing cores for “Hot-box” and "Cold-box” processes. Composition of molding and core sands for “Hot-box” and “Cold-box” processes. Different groups of catalysts belonging to cementing

One describes the effect of salts on the curing process of sand –resin mixtures.

One describes the principles of manufacturing rods for “Hot-box” and “Cold-box” process. One leads compositions of molding and core sands for “Hot-box” and "Cold-box” process. One explains the principle of catalysts at “Hot-box” and “Cold-box” processes.

231


systems for “Hot-box” and “Cold-box”.

Section 6 Physical and chemical processes of hardening mixtures of nonorganic binding materials

Topic 6.1. Molten glass mixtures

The composition, structure and methods of manufacturing molten glass. Classification of molding and core mixtures thereof. Curing mechanisms of molding and core sands are based on its basis. It describes the structure, the structure and methods of manufacturing soluble glass.

One characterizes the composition, the structure and methods of manufacturing molten glass, the classification and chemical reactions, the description of curing mechanisms of molding and core sands based on liquid glass.

One describes the composition, the structure and methods of manufacturing molten glass. One classifies molding and core sands based on liquid glass. One makes chemical reactions and describes curing mechanisms of molding and core sands based on liquid glass.


Investigation of the influence of the amount of liquid glass and the type of processing on the physical and mechanical properties of soluble glass mixtures.

One researches the effect of the amount of liquid glass and the type of processing on physical and mechanical properties of soluble glass mixtures.

One analyzes the effect of the amount of liquid glass and the type of processing on physical and mechanical properties of soluble glass mixtures.

Topic 6.2. The phosphate mixtures

232


Classification of phosphate bonds depending on the chemical composition and the purpose. Composition of molding and core sands on their basis. Curing mechanism of molding and core sands based on phosphate bonds.

One classifies phosphate mixtures. One classifies phosphate bonds depending on the chemical composition and the purpose. One describes compositions of molding and core sands based on phosphate bonds. One makes chemical reactions and describes curing mechanisms of molding and core sands based on phosphate bonds.


Learning methods of curing mixtures. Determination of their basic properties.

One researches the means of curing mixtures and determines their basic properties.

One analyzes the ways of curing mixtures. One determines their underlying properties.

Topic 6.3. Polycondensation mixtures

Classification of mixtures of polycondensation. The compositions, methods for creating different soluble glass, phosphate, cement mixtures, their applications, advantages and disadvantages.

One describes unit molding sands. One classifies polycondensation mixtures. One describes their composition and scope. One explains their advantages and disadvantages. One refers to the methods for producing polycondensation mixtures.

Section 7. Basic theory of the formation of the properties of molding sands

Topic 7.1. Unit sands

233


The purpose of unit sands and regularities in the formation of their properties. Different compositions (depending on the compaction techniques, the form and dimensions of the casting alloy) of unit sands and their mechanisms of formation properties.

One characterizes polycondensation mixtures.

One explains the purpose of unit sands and regularities in the formation of their properties. One describes compositions of unit sands. One shows ways of their seal.

Topic 7.2. Facing molding sand (FMS) and filler sand (FS)

Compositions of facing molding sand and filler sand. A wide range of facing molding sands and filler sands, patterns of their physical and mechanical properties and applications in the production of castings.

One explains facing molding sands and filling molding sands.

One describes compositions of facing molding and filling sands. One names their application in the manufacture of casting. One explains the patterns of formation of their physical and mechanical properties.


Selection and justification of the form of mixtures of various alloys and sizes of casts.

Selection and justification of the variety of mixtures for various alloys and sizes of cast.

One selects and justifies the kind of mixtures for various alloys and sizes of casts.

Topic 7.3. Quality control of molding and core sands

234


Test methods of molding and core sands. Purpose and use of devices for these purposes.

One expounds the test methods of molding and core sands.

One refers to test methods of molding and core sands. One describes the purpose and use of devices for these purposes.

Section 8. The mechanisms of defect formation of castings

Topic 8.1. Gas conditions of foundry mold

Gas dynamic processes in the mold during periods of melt loading, crystallization and cooling of the casting.

One explains gas conditions for foundry mold.

One explains the nature of dynamic processes occurring in the mold during periods of pouring it melt loading, crystallization and cooling of the casting.


Determining the gas vapour capacity of mixtures and their gas permeability.

One determines the gas vapour capacity of mixtures and their gas permeability.

One defines the gas vapour capacity of mixtures and their gas permeability.

Topic 2. The mechanisms of gas formation in the casting defects

Classification of gas defects in the castings and their identification. Basic laws of formation of gas in the casting defects and methods how to avoid them.

One describes the mechanisms of cast gas defects formation.

One classifies gas defects. One describes the methods of identifying them. One explains the basic laws of formation of gas defects in castings and names methods of preventing them.


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A study of the major defects in casts and measures to prevent them.

One identifies the main casting defects and researches measures to prevent them.

One identifies major defects in castings and justifies measures to prevent them.

Topic 8.3. Types of burning-on of casts and methods of its prevention. Parting materials and nonstick coating

General theoretical understanding of the mechanisms of formation of metal penetration on the surface of the casts. Creation of mechanical (metalized), chemical and thermal burning-on. The differences in the methods of struggle with this defect on the surface of steel and iron casts. The compositions and the properties of nonstick coatings.

One describes the varieties of casting burning-on and methods of its prevention. The description of parting materials and nonstick coating.

One explains the reasons for the formation of metal penetration on the surface of steel and iron casts. One explains the nature of the hydrodynamic, thermo-chemical and thermal interactions in the contact zone “liquid-alloy- foundry mold”. One classifies nonstick coating, compositions and their physical-mechanical properties.

Laboratory work No 14

The study of types of burning-on on surfaces of casts and measures to combat it.

One researches the varieties of casting surfaces burning-on and measures of combating it.

One determines types of burning-on on surfaces of casts and justifies measures to combat it.

Topic 8.4. The mechanisms of formation of pinchers and cutting-out and methods of dealing with them

Thermal and physical processes occurring in the foundry mold. Terms and causes of the formation of

One describes the mechanisms of formation of pinchers and cutting out and

One explains the nature of physical thermal processes taking place in the foundry mold in the periods of filling and solidification and also

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pinchers and cutting-out, methods of effective prevention.

methods of dealing with them. explains the reasons for the formation of pinchers and cutting-out, methods of effective prevention.


The study of technological factors affecting the formation of pinchers and cutting-out, effective methods of prevention.

One researches technological factors affecting the formation of pinchers and cutting-out and effective methods of their prevention.

One analyzes technological factors affecting the formation of pinchers and cutting-out, proves effective methods of prevention.

Section 9. Modern methods of regenerating molding sands and mixtures

Topic 9.1. Preparation of reconditioned sand for recycling

The principles of preparation of reconditioned sand for recycling. Flow diagrams of opening, magnetic separation, averaging humidity, dust control and quality control of the reconditioned sand. The tooling needed for the implementation of these processes.

One analyzes the principles of preparation of reconditioned sand for recycling, composition of flow diagrams of opening, magnetic separation, averaging humidity, dust control and quality of reconditioned sand.

One explains principles of preparation of reconditioned sand for recycling. One composes flow diagrams of opening, magnetic separation, averaging humidity, dust control and quality control of the reconditioned sand. It introduces examples for the tooling needed for the implementation of these processes.


Study of the principles of preparation of reconditioned sand for recycling

One researches the principles of preparation of reconditioned sand for

One analyzes the principles of preparation of reconditioned sand for recycling and chooses the

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and tooling needed for the implementation of these processes.

recycling and the equipment necessary for the implementation of these processes.

tooling needed for the implementation of these processes.

Topic 9.2. Physical and chemical processes occurring in the separation of films of binders from the surface of fillers of molding and core sands

The nature of physical and chemical processes occurring during the regeneration of molding and core sands. Mechanisms of pneumatic, mechanical, thermal, hydraulic and comprehensive regeneration of different types of core and molding sands.

One researches the nature of physical and chemical processes occurring during the regeneration of molding and core sands.

One explains the nature of the physical and chemical processes occurring during the regeneration of molding and core sands and the mechanisms of pneumatic, mechanical, thermal, hydraulic, and comprehensive regeneration of different types of core and molding sands.

Section 10. The technology of manual methods of manufacture of foundry molds and cores

Topic 10.1. Molding equipment and tools

Information about the main types of molding tooling (foundry flasks, models, chaplets, fittings and etc.) and tools (tampers, lancets, prods, brushes, etc.). Purpose, design of the main types of mold equipment and tools.

One states the purpose and design of the main types of molding equipment and tools.

One explains purpose and design of the main types of molding tooling (frames, models, chaplets, fittings and etc.) and tools (tampers, lancets, prods, brushes, etc.).

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Topic 10.2. Varieties of hand molding in foundry flasks

Basics of hand molding. The principles of molding on the ground, forming in two or more flasks, molding with trimming, turn-over molding, forming on rotating and long-drawn templates.

One describes the varieties of hand molding in foundry flasks.

One explains schemes of molding on the ground, forming in two or more flasks, molding with trimming, turn-over molding, forming on rotating and long-drawn templates. One gives schemes of molding.

Topic 10.3. Schemes of sites organization for hand molding

Principles of creation of hand-formed sites depending on the molding method. Schemes of hand-formed sites.

One interprets the organization of hand molding sites.

One explains schemes of hand-formed sites, depending on the molding method and organization of schemes of hand-formed sites.

Section 11. The technology of mechanized and automated methods of forming

Topic 11.1. Pressing methods of luting of foundry molds

The basic technology of making a foundry mold by using the upper and lower compression, two-way consolidation with profiled plate and multiplunger head. Schemes of making a foundry mold by using the upper and lower compression, two-

One describes the pressing methods of luting foundry molds.

One explains principles of making a foundry mold by using the upper and lower compression, two-way consolidation with profiled plate and multiplunger head. One composes schemes of making a foundry mold by using the upper and lower compression, two-way consolidation with profiled plate and

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way consolidation with profiled plate and multiplunger head.

multiplunger head.

Topic 11.2. Dynamic methods of consolidation of foundry mold

The basic technology of making a foundry mold by shaking, chattering, pneumo impulse, gas impulse and etc. Schemes of manufacturing foundry molds by shaking, chattering, pneumo impulse, gas impulse.

The knowledge of dynamic methods of consolidating foundry molds.

One explains principles of making a foundry mold by shaking, chattering, pneumo impulse, gas impulse and etc. One composes schemes of making a foundry mold by shaking, chattering, pneumo impulse, gas impulse and etc.

Topic 11.3. Combined methods of foundry molds

The basic technology of making a mold by shaking with prepressing, air-sand blower method and compacting method, by air stream followed by compacting. Schemes of making a foundry by shaking with prepressing, air-sand blower method and compacting method, by air stream followed by compacting.

One describes a combined method of foundry molds manufacturing.

One explains principles of making a foundry mold by shaking with prepressing, air-sand blower method and compacting method, by air stream followed by compacting. One composes schemes of making a foundry mold by shaking with prepressing, air-sand blower method and compacting method, by air stream followed by compacting.


Skills acquisition of making foundry One manufactures foundry molds in One manufactures foundry molds in various ways.

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molds by various methods. various ways.

Topic 11.4. Basics of creating automatic molding lines

Requirements for the sands produced on automatic molding line (AML). Basic principles of assembly equipment for the AML.

One researches the requirements for automatic molding lines’ sands.

One describes requirements sands AML. One sets out the principles of a complete set of equipment for the AML.

Section 12. Technology of core molding

Topic 12.1. Manual methods of core molding

Fundamentals of manual methods of core molding of any complexity including the cores of ceramic masses for casting from special alloys (ShawProcess). Features of core molding which are curable by thermal drying. Technology processes of drying cores.

One characterizes methods of core molding of any complexity, including the cores of ceramic masses for casting form special alloys (ShawProcess).

One methods of core molding of any complexity, including the cores of ceramic masses for casting from special alloys (ShawProcess). One explains features of core molding which are curable by thermal drying. One explains technology processes of drying cores.

Topic 12.2. Air sand blower and sand shooter methods for core molding

Technological schemes of air sand blower and sand shooter processes of cores consolidation. Sand

One explains mechanisms and draws up schemes of air sand blower and sand shooter processes of cores consolidation.

One explains mechanisms and draws up schemes of air sand blower and sand shooter processes of cores consolidation. One names sand formulation and its

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formulation. Requirements for properties of core sands for these processes.

properties of air sand blower and sand shooter processes of cores consolidation.


Acquisition skills of cores molding. One manufactures cores. One manufactures cores.

Topic 12.3. Technology of coloring, drying, finishing and quality control of cores

Fundamentals of technology of coloring, drying, finishing and quality control of cores. Robotic systems of finishing operations of core molding.

One describes technologies of coloring, drying, finishing and quality control of cores

One describes technologies of coloring, drying, finishing and quality control of cores. One gives examples of robotic systems of finishing operations of core molding.

Section 13. Fundamentals of foundry tooling

Topic 13.1. Fundamentals of design patterns and core boxes

Theoretical foundations of design patterns and core boxes. Choosing the parting plane of models, forms, appointment of allowances for mechanical treatment, casting slopes, the size of core characters and others. (Foundry and model instructions).

One expounds the choice of parting plane of models, forms, appointment of allowances for mechanical treatment, casting slopes, the size of core characters and others.

One explains and performs scheme of purpose foundry and model instructions. One chooses parting plane of models, forms, appointment of allowances for mechanical treatment, casting slopes, the size of core characters and others.

Topic 13.2. Methods for producing foundry patterns and core boxes

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Modern technologies of wooden, metal, polymeric models and core boxes using computer controlled machines and special software.

One expounds the modern technology of wood, metal, polymer models and core boxes.

One explains the modern technology of wood, metal, polymer models and core boxes using computer controlled machines tools and used in these processes software.

Test

Topic 14. The technology of finishing operations of manufacturing castings

Topic 14.1. Casting of foundry molds

The basic technology of casting foundry molds. Features of ladles design and automatic casting devices. The main types of ladles.

One describes the basics of technology of casting of foundry molds.

One explains the basics of technology of casting of foundry molds. One explains design features of ladles and illustrates the main types of ladles. One describes the structure and function of the automatic casting devices. One gives examples of the automatic casting devices.

Topic 14.2. Technology knockout of casting from molds, core knockout from casting

The basic technologies of knockout of casting from molds, core knockout from casting. The main types of knock-out grids, devices for extrusion of coma, hydraulic and electro hydraulic installations. The features of

One describes the knockout technology of casting from molds, core knockout from casting.

One explains basic technologies of knockout of casting from molds, core knockout from casting and features of their design and functions of knock-out grids, for extrusion of coma, hydraulic and electro hydraulic installations.

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their design and functions.

Topic 14.3. Cropping, cleaning and quality control of casting

The basic technology of cropping and cleaning of castings in small-scale and mass production (including the use of robots and manipulators). The principles of grading castings and methods of reconstruction.

One describes cropping and cleaning and control of castings in small-scale and mass production.

One explains the basics of cropping and cleaning of castings in small-scale and mass production. One gives examples of tooling used in processes cropping and cleaning of castings. One explains principles of grading castings and methods of reconstruction.


Selection of technological parameters of casting, knockout of casting from molds.

Selection of technological parameters of casting, knockout of casting from molds.

One chooses technological parameters of casting, knockout of casting from molds.

Section 15. Environmental aspects of manufacturing technologies of castings

Topic 15.1. The main types of harmful substances formed during the molding-sand preparation of foundry molds and cores

Information about the environmental aspects of technology of casting, the main types of harmful substances formed during the molding sand preparation of foundry molds and cores. Constructions, principles of

One researches and discovers the main types of harmful substances formed during the molding-sand preparation of foundry molds and cores.

One explains the environmental aspects of technology of casting, the main types of harmful substances formed during the molding-sand preparation of foundry molds and cores. One describes constructions, principles of operation of treatment plants.

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operation of treatment plants.

Topic 15.2. Gas evaluation by molding and cooling of castings

Classification of the gaseous emissions depending on the composition of molding and core sands. Basic methods of reducing gas emissions and recycling.

One classifies the gaseous emissions in the manufacture of castings depending on the composition of molding and core sands.

One classifies the gaseous emissions in the manufacture of castings depending on the composition of molding and core sands. One describes the basic methods to reduce gas emissions and recycling.

Topic 15.3. Prospects of development of the foundry industry

Major trends occurring in the global industry and role of foundry industry in these processes.

One expounds development prospects of the foundry industry.

One analyzes the main trends occurring in the global industrial-raising and the role of the foundry industry in these processes.

Course work

Design technology of casting. Selecting parting of connectors and place of supply feeders, calculation of elements of the gating-feeder system. Design of tooling (models, core boxes). Forming technology, the production of cores, assembly and filling of the mold. Calculation of processes hydrodynamics of filling

Course project. Under the execution of the course-project a student designs the technology of manufacturing castings. One selects the parting of connectors and place of supply feeders, calculates the size of the elements of the gating-feeder system. On the basis of calculations he designs tooling and describes the technology of forming, core making, assembly and filling of the mold, finishing operations and quality control of concrete casting. One performs drawings

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molds and crystallization of castings, finishing operations and quality control of concrete casting. Graphic wordage of the course-project is 3-4 sheets (drawing of casting, assembly of models at the plate, core box, and mold assembly).

of casting (application of casting and model instructions), installation of models at the plate, core box mold assembly.

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Guidelines

The following forms of organization of teaching are recommended in order to implement a training program on discipline “Theory and Technology of foundry production”: lectures, workshops, field trips, laboratory classes.

Taking into account the nature and complexity of the content of educational material the following teaching methods are recommended: lectures and conversations, discussions, decisions of situational tasks, analysis of work situations, role-playing and simulation games, brainstorming, pre-presentations of material, work in small groups and others.

Forms of organization of cognitive activities are advisory. The number of hours to study sections can be changed while maintaining the minimum of content.

This training program provides:

- Training students in system analysis of technology of casting from various alloys;

- The study of the mechanisms and physical phenomena occurring in the manufacture of molds, cores, casts.

Academic discipline “Theory and Technology of foundry production” is based on the knowledge gained from studying such disciplines as “Chemistry”, “Mathematics”, “Physics”, “Drawing”, “Basics of technical mechanics”.

The control of this academic discipline provides interim attestation which has the main forms as control work, examination, testing.

In implementing the training program is provided for carrying out:

- control work - 1;

- test - 1;

- examination - 1.

Educational organizations must develop in working education program competence-oriented tasks in the test form.

Tests should be presented according to sections, topics and have three mainly difficulty level (minimum, medium and hard).

The knowledge gained from the study of discipline used to study the following modules:

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- Automation of the foundry industry;

- Foundry machinery;

- Design of foundry tooling.

In the study of module it is necessary to carry out the integration of academic disciplines to general professional and special cycles.

The control of this academic discipline provides for interim assessment, basic forms of which are the following: intermediate assessment papers, exam and tests.


- Intermediate assessment papers - 1;

- Course project – 1;

- Credit – 1;

- Exam – 1;



As a result of study of the discipline the student must know:

- Rules of selection of materials for the manufacture of molds and cores;

- The main processes: molding-sand preparation, manufacture of molds and cores, casting, knockout, cropping and cleaning castings;

- Methods for quality control of castings;

- Standards in the field of materials technology and casting processes;

The student must be able to:

- Design engineering processes for castings;

- Identify and analyze the basic physical and mechanical properties of foundry and core sands;

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- calculate the basic elements and design gating system for the manufacture of castings from various alloys;

- Issue documentation on manufacturing of modeling tooling and casts;

- Organize the process of manufacturing casts, monitor their quality with minimum maintenance cost;

- analyze the prospects of technology of foundry of and necessary to the process of obtaining new materials and tooling;

- Choose effective criteria for technology development and design of tooling to produce castings conforming to the conditions of the modern foundry;

- Improve and streamline current processes on the basis of a systematic approach to the analysis of raw materials, the existing technological processes and quality requirements for the obtained products.

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FOUNDRY ALLOYS AND MELTING

The purpose of the study of the discipline is to develop the students’ knowledge in the field of the structure and properties of metal melts, casting,

mechanical and operational properties of carbon-iron and non-ferrous metals and alloys, physical and chemical bases of the smelting processes.


Topic

Number of hours

allIncluding for

laboratory works

1 2 3

Introduction 1

1. The modern concept of the structure of metallic melts 1

2. Physical and electromagnetic methods of influence on the molten metal

2

3. General description of the properties of casting alloys. Fluidity of metals and alloys

4 2

4. The formation of gas porosity. The insoluble and poorly soluble non-metallic inclusions

6 2

5. Types and mechanism of segregation 2

6. Basic concepts of shrinkage 6 4

7. The mechanical, thermo mechanical and phase voltage. Temporary and residual stresses.

2

8. Types of modifiers. Macro- and micro-alloying. Effect of modifying on the properties of the alloys

6 2

9. Casting carbon steel 4 2

Control work 1

10. Alloy structural steel 5 2

Total 40 14

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1 2 3

11. High-alloy casting steel with special properties 6 2

12. Classification of cast irons. Structure formation. Graphite is in cast iron

4 2

13. Grey cast iron with lamellar graphite. Malleable iron with flake graphite

6 2

14. High-strength cast iron with spheroid and vermicular graphite form. Alloyed cast iron

6 2

15. Aluminium alloys 4 2

16. Copper-based alloys 6 2

17. Casting alloys based on magnesium, titanium, zinc and nickel

6 2

18. The structure and properties of the phases involved in the process of melting the casting alloy

2

19. The mechanism of the process, the main types of interaction of phases in melting

2

20. Characteristics of processing foundry alloys in the liquid state

2

21. The classification of iron smelting processes 1

22. Charging materials, ferroalloys, fluxes 1

23. Fuel used in melting aggregates 1

24. Smelting iron in cupola furnaces 3 2

25. Features of acidic and basic processes of smelting iron in a cupola furnace

1

26. Melting of cast iron of different grades 2

27. Melting of cast iron in electric melting units 1

28. Heat of steel in electric arc furnaces 3 2

29. Heat of steel in induction furnace units 3 2

30. Preparation of steel of high quality 1

Control work 1

31. Melting of aluminum and magnesium alloys 2

32. Melting of copper and nickel alloys 2

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1 2 3

33. Melting of lead and zinc alloys 2

Total 68 20

In all 108 34

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Introduction

The structure and content of the discipline “Foundry alloys and melting”. The purpose and objectives of the course. The role of the discipline in the formation of professional knowledge, skills of students. Prospects of development of foundry alloys and melting process.

One expresses general judgments on content of the discipline “Foundry alloys and melting”, the purpose and objectives of the course, the role of the discipline in the formation of professional knowledge, skills of students.

One expresses general judgments on content of the discipline “Foundry alloys and melting”, the purpose and objectives of the course, the role of the discipline in the formation of professional knowledge, skills of students and names prospects of development of foundry alloys and melting process.

Topic 1. The modern concept of the structure of metallic melts

Fluctuation, molecular, colloidal, cluster theory of the structure and other theories of metallic structures. Homogeneous and heterogeneous nucleation and crystal growth in the liquid phase. The role of super cooling, formation rate and the growth of centers of crystallization. Consistent and volume

One expounds modern concepts of the structure of metallic melts.

Ones expresses general judgments on fluctuation, molecular, colloidal, cluster theory of the structure and other theories of metallic structures, describes homogeneous and heterogeneous nucleation and crystal growth in the liquid phase, the role of super cooling, formation rate and the growth of centers of crystallization, consistent and volume crystallization. One names influence of the state of the alloy on the phase diagram and the cooling rate on the character of

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crystallization. Influence of the state of the alloy on the phase diagram and the cooling rate on the character of the crystallization process.

the crystallization process.

Topic 2. Physical and electromagnetic methods of influence on the molten metal

The principles of electromagnetic methods of influence on the molten metal. Management of fluidity process and control of occupancy forms. Effects on the hydrodynamics of the melt, the structure and properties of metals. Intensification of processes of heat and mass transfer in the process of casting. Thermo cycling of the melt. Vibration treatment of the melt.

One describes physical and electromagnetic methods of influence on the molten metal.

One explains principles of electromagnetic methods of influence on the molten metal, describes management of fluidity process and control of occupancy forms, names effects on the hydrodynamics of the melt, the structure and properties of metals, intensification of processes of heat and mass transfer in the process of casting, thermo cycling of the melt, vibration treatment of the melt.

Topic 3. General description of the properties of casting alloys. Fluidity of metals and alloys

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The value of fluidity for castings manufacturing practices. The concept of zero, true, conditionally true and practical fluidity. Samples for determination. A mechanism of stop flow. The factors affecting the fluidity.

One characterizes the properties of casting alloys and fluidity of metals and alloys.

One names the value of fluidity for castings manufacturing practices. The concept of zero, true, conditionally true and practical fluidity and describes samples for determination, a mechanism of stop flow, and the factors affecting the fluidity.


The study of fluidity of alloys. One expounds the principles of alloys’ fluidity.

One analyses fluidity of alloys.

Topic 4. The formation of gas porosity. The insoluble and poorly soluble non-metallic inclusions

Possible forms of the existence of gas in metals and alloys. Sources of gases entering into the metal. Dissolution of gases in the metals. Blowholes of endogenous and exogenous nature. Effect of gases on the properties of the alloys. The mechanism of formation of gas porosity. Precautions against the

One describes forms of the existence of gas in metals and alloys, sources of gases entering into the metal.

One names possible forms of the existence of gas in metals and alloys, sources of gases entering into the metal, describes dissolution of gases in the metals. Blowholes of endogenous and exogenous nature, effect of gases on the properties of the alloys, the mechanism of formation of gas porosity, precautions against the ingress of gases into the metal and preventing their separation during solidification, methods for determination of gas saturation in the alloys. One explains classification of non-metallic

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ingress of gases into the metal and preventing their separation during solidification. Methods for determination of gas saturation in the alloys. Classification of non-metallic inclusions. The ways to reduce the number of nonmetallic inclusions in metals and alloys.

inclusions, the ways to reduce the number of nonmetallic inclusions in metals and alloys.

Laboratory work No.2

The determination of gas saturation in the alloys.

One determines gas saturation in the alloys. One determines gas saturation in the alloys.

Topic 5. Types and mechanism of segregation

The mechanism of rise of intracrystalline, zonal (forward and reverse) and gravitational segregation. Segregated spot. The distribution coefficient and its role in the phase-separation processes. Effect of phase segregation on the properties of castings and the control

One describes types and mechanisms of segregation.

One describes of rise of intracrystalline, zonal (forward and reverse) and gravitational segregation. Segregated spot and names the distribution coefficient and its role in the phase-separation processes. Effect of phase segregation on the properties of castings and the control measures with it.

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measures with it.

Topic 6. Basic concepts of shrinkage

The volume, linear, free and hindered shrinkage. The methods for determining the magnitude of shrinkage. Shrinkage in the liquid state and at over-solidification, shrinkage defects in castings. Internal and external shrinkage shells, mechanism of their formation. Concentrated shrink hole and shrinkage porosity and their relationship with the position of the alloy on the phase diagram and the cooling rate. The concept of risering and the formation of their shrinkage defects. Shrinkage of casts in a solid state. Accounting for the shrinkage in the manufacture of pattern tooling.

One expounds concepts of shrinkage. One describes the volume, linear, free and hindered shrinkage, the methods for determining the magnitude of shrinkage, shrinkage in the liquid state and at over-solidification, shrinkage defects in castings, internal and external shrinkage shells, mechanism of their formation, concentrated shrink hole and shrinkage porosity and their relationship with the position of the alloy on the phase diagram and the cooling rate. One proves the concept of risering and the formation of their shrinkage defects. Shrinkage of casts in a solid state, accounting for the shrinkage in the manufacture of pattern tooling.

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The study of volume shrinkage of alloys.

The study of volume shrinkage of alloys. One proves volume shrinkage of alloys.


The determination of linear shrinkage of alloys.

One describes linear shrinkage of alloys. One determines linear shrinkage of alloys.

Topic 7 The mechanical, thermo mechanical and phase voltage. Temporary and residual stresses.

The mechanism of formation of residual stresses. Factors affecting their value and measures to reduce them. Methods for defining division tendency of alloys to residual stresses. Removal of residual stresses. Casting strain in the form by mechanical processing, storage and use. Hot and cold cracks in castings. Hot cracking in the casting as a result of mechanical stresses, low

One characterizes mechanical, thermo-mechanical and phase voltages. A description of temporary and residual voltages.

One describes mechanism of formation of residual stresses, factors affecting their value and measures to reduce them, methods for defining division tendency of alloys to residual stresses, removal of residual stresses. One judges casting strain in the form by mechanical processing, storage and use, hot and cold cracks in castings, hot cracking in the casting as a result of mechanical stresses, low mechanical properties in the temperature range of brittleness and uneven properties of castings (strain concentration) and hot brittleness of alloys and its evaluation.

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mechanical properties in the temperature range of brittleness and uneven properties of castings (strain concentration). Hot brittleness of alloys and its evaluation.

Topic 8. Types of modifiers. Macro- and micro-alloying. Effect of modifying on the properties of the alloys

Modifiers of the first and second type. Selection of the modifiers of the first kind. The modifiers that affect the shape of non-metallic inclusions. Nan modification. Surface modification of casts and ways of its performance.

One explains selection of the modifiers of the first kind, nanomodification, surface modification of casts and ways of its implementation..

One describes types of modifiers. One explains selection of the modifiers of the first kind. The modifiers that affect the shape of non-metallic inclusions, nanomodification, surface modification of casts and ways of its performance.


The study of effect of overheating, cooling rate, modifying the structure and properties of cast iron.

One describes the effect of overheating, cooling rate, modifying the structure and properties of cast iron.

One can characterize the effect of overheating, cooling rate, modifying the structure and properties of cast iron.

Topic 9. Casting carbon steel

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Classification of cast steel. Chemical composition, labeling and mechanical properties of carbon steel casting. Casting properties. The influence of impurities on the properties of steels. Segregation. Gas and nonmetallic inclusions in the castings. Refining and modification of steels.

One describes the classification of cast steel, chemical composition, labeling and mechanical properties of carbon steel casting, casting properties, the influence of impurities on the properties of steels.

One explains classification of cast steel, chemical composition, labeling and mechanical properties of carbon steel casting, casting properties, the influence of impurities on the properties of steels.


The research of structure and properties of casting carbon steel.

One analyses structure and properties of casting carbon steel.

One analyses structure and properties of casting carbon steel.

Topic 10. Alloy structural steel

The chemical composition, marking. Characteristics of mechanical and casting properties of manganese, silicon and manganese, chromium, nickel-chromium, vanadium, copper-bearing casting steel.

One expounds chemical composition, marking and characteristics of mechanical and casting properties of manganese, silicon and manganese, chromium, nickel-chromium, vanadium, copper-bearing casting steel.

One describes chemical composition, marking. Characteristics of mechanical and casting properties of manganese, silicon and manganese, chromium, nickel-chromium, vanadium, copper-bearing casting steel, names application of alloyed steels and explains interaction of iron in iron-carbon alloys with alloying elements, classification of alloyed steels, influence on

260


Graphitized steel. Application of alloyed steels. Interaction of iron in iron-carbon alloys with alloying elements. Classification of alloyed steels. Influence on the element structure, mechanical and technological properties of steels. Features of crystallization and the impact of thermal treatment on the structure and properties of steels.

the element structure, mechanical and technological properties of steels.


The study of structure and properties of highly-alloyed manganese steel.

One analyses structure and properties of highly-alloyed manganese steel.

One analyses structure and properties of highly-alloyed manganese steel.

Topic 11. High-alloyed casting steel with special properties

Classification according to composition, designation, marking. Characteristics of mechanical, casting and special properties of chromium corrosion-resistant and heat-

One characterizes high-alloyed casting steel with special properties.

One explains classification according to composition, designation, marking, characteristics of mechanical, casting and special properties of chromium corrosion-resistant and heat-resistant steels, nickel-chromium martensitic and austenitic corrosion-resistant and heat-

261


resistant steels, nickel-chromium martensitic and austenitic corrosion-resistant and heat-resistant steels, high-manganese wear-resistant steel.

resistant steels, high-manganese wear-resistant steel.


The study of structure and properties of the steels and alloys with special properties.

One analyses the structure and properties of the steels and alloys with special properties.

One analyses the structure and properties of the steels and alloys with special properties.

Topic 12. Classification of cast irons. Structure formation. Graphite is in cast iron

Classification of cast irons by carbon state, graphite shape and other characteristics of the structure. The impact on the structure on the complex of mechanical and performance properties. Effect of elements on the position of the critical points of the iron-carbon system. The phase composition of cast iron. Formation of the primary structure of the iron. The concept

One classifies cast irons by carbon state, graphite shape and other characteristics of the structure, the impact of the structure on the complex of mechanical and performance properties.

One explains classification of cast irons by carbon state, graphite shape and other characteristics of the structure. The impact on the structure on the complex of mechanical and performance properties. One defines eutectoid transformation in white and gray cast iron. Effect of silicon on the structure, analysis of the effect of cooling rate on the structure of thermo-kinetic diagrams of austenite decomposition, structural diagrams of cast iron, graphite formation in cast iron, the shape and location of the graphite precipitates, influence of graphite inclusions in the physical-

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of the degree of eutectoid properties and carbon equivalent. The formation of secondary structure in cast iron. Isolation of secondary phases upon cooling. Eutectoid transformation in white and gray cast iron. Effect of silicon on the structure. Analysis of the effect of cooling rate on the structure of thermo-kinetic diagrams of austenite decomposition. Structural diagrams of cast iron. Graphite formation in cast iron. The shape and location of the graphite precipitates. Influence of graphite inclusions in the physical-mechanical, technological and operational properties. Classification of elements by their influence on the process of graphitization. The mechanism and kinetics of

mechanical, technological and operational properties.

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the process of graphitization.


The study of the structure and properties of cast irons.

One analyses the structure and properties of cast irons.

One analyses the structure and properties of cast irons.

Topic 13. Grey cast iron with lamellar graphite. Malleable iron with flake graphite

Chemical composition, structure and mechanical properties of cast iron with lamellar graphite form. Application of gray iron castings. Peculiarities of malleable cast iron. The graphitizing annealing, the annealing modes, accelerate of the process of annealing. Casting properties of malleable cast iron. The use of castings made of malleable cast iron.

One describes chemical composition, structure and mechanical properties of cast iron with lamellar graphite form.

One describes chemical composition, structure and mechanical properties of cast iron with lamellar graphite form. One names application of gray iron castings, the use of castings made of malleable cast iron, discusses peculiarities of malleable cast iron.


264


The study of methods for producing high-strength of cast iron.

One characterizes methods for producing high-strength of cast iron.

One characterizes methods for producing high-strength of cast iron.

Topic 14. High-strength cast iron with spheroidal and vermicular graphite form. Alloyed cast iron

Chemical composition, structure and mechanical properties of high-strength cast iron with spherical graphite form. Casting properties and application of high-strength cast iron. Compacted graphite iron, the chemical composition, properties and applications. Synthetic cast iron. Alloyed cast iron. Classification. Physical and mechanical, operational and casting properties of chromium, siliceous, aluminum, nickel, vanadium cast iron. Application of alloyed cast iron.

One describes chemical composition, structure, mechanical and molding properties of high-strength cast iron with spheroidal and vermicular graphite form.

One describes chemical composition, structure and mechanical properties of high-strength and with spherical graphite form cast iron. One names field of application of high-strength and alloyed cast iron. One explains classification. Physical and mechanical, operational and casting properties of chromium, siliceous, aluminum, nickel, vanadium cast iron.


The study of the structure and One expounds the structure and properties One analyses the structure and properties of special

265


properties of special alloyed cast iron.

of special alloyed cast iron. alloyed cast iron.

Topic 15. Aluminium alloys

Classification, chemical composition and marking of aluminum alloys. The structure of the alloys. Characteristics of mechanical, operational and casting properties of the alloys. Justification of the choice of alloying elements.

One describes characteristics of mechanical, operational and casting properties of the alloys, justification of the choice of alloying elements.

One explains classification, chemical composition and marking of aluminum alloys, the structure of the alloys and describes characteristics of mechanical, operational and casting properties of the alloys, justification of the choice of alloying elements.


The study of the structure and properties of the aluminium-based alloys.

One analyses the structure and properties of aluminium-based alloys

One analyses the structure and properties of aluminium-based alloys.

Topic 16. Copper-based alloys

General characteristics of the properties of copper and its interaction with other elements. The main alloying elements in the copper alloys. Classification

One describes copper-based alloys. One names the properties of copper and its interaction with other elements. The main alloying elements in the copper alloys, explains classification of alloys and labeling. One describes chemical composition, structure, mechanical, operational and alloys casting

266


of alloys and labeling. Casting bronzes alloys and their chemical composition, structure, mechanical, operational and alloys casting properties. Casting brass, chemical composition, structure and properties. Application area.

properties of copper-based alloys, their application area.


The study of the structure and properties of copper-based alloys.

One analyses the structure and properties of copper-based alloys.

One analyses the structure and properties of copper-based alloys.

Topic 17. Casting alloys based on magnesium, titanium, zinc and nickel

General description of properties of magnesium and its interaction with other elements. The proof for the choice of the main alloying elements. Chemical composition, labeling alloys. The structure of the alloys. Characteristics of mechanical, operational and casting

One describes chemical composition, structure, labeling and characteristics of mechanical, operational and casting properties of the alloys based on magnesium, titanium, zinc and nickel.

One names properties of magnesium, titanium, zinc and nickel their interaction with other elements. One describes chemical composition, structure, labeling and characteristics of mechanical, operational and casting properties of the alloys based on magnesium, titanium, zinc and nickel.

267


properties of the alloys. Scope of the alloys. Titanium casting alloys. The chemical composition, structure and mechanical properties of casting alloys. Application area. Zinc alloys. The chemical composition, structure and casting properties. Scope of the alloys. Nickel casting alloys. General characteristics of the properties of nickel and its interaction with other elements. The main alloying elements in nickel alloys, their influence on the mechanical, special and casting properties. Classification of alloys by chemical composition and purpose, marking alloys. Corrosion-resistant, heat-resistant nickel alloys. Principles of modification, chemical composition, structure,

268


mechanical and casting properties.


The research of the structure and properties of the alloys based on magnesium, titanium, zinc and nickel.

One analyses the structure and properties of the alloys based on magnesium, titanium, zinc and nickel

One analyses the structure and properties of the alloys based on magnesium, titanium, zinc and nickel.

Topic 18. The structure and properties of the phases involved in the process of melting the casting alloy

General characteristics of the smelting processes. Classification of the smelting processes and methods for their implementation, the parameters of the melting process. General characteristics of the physical and chemical processes in melting furnaces while melting cast alloys. Thermodynamics of the melting process. Features of the processes of melting cast alloys. Nature of the liquid state. Glass State. Internal energy and

One describes characteristics of the physical and chemical processes in melting furnaces while melting cast alloys, thermodynamics of the melting process, and features of the processes of melting cast alloys.

One explains characteristics of the smelting processes and methods of their performance, the parameters of the melting process. One describes characteristics of the physical and chemical processes in melting furnaces while melting cast alloys, thermodynamics of the melting process, and features of the processes of melting cast alloys.

269


enthalpy as a function of the state. Hess' law. Kirchhoff's equation. The solid phases. Liquid wastes. Gas phase. Thermodynamics of interaction of phases. The phase rule. Distribution law. Thermodynamics of chemical equilibrium. The law of mass action. The equilibrium constant. The measure of the chemical affinity. Determining the direction of process flow. Methods for calculating the equilibrium constant. Le Chatelier's principle. The rate of chemical reactions. The kinetic and diffusion region. Determination of efficiency of the components in the molten metal and melted slag.

Topic 19. The mechanism of the process, the main types of interaction of phases in melting

The kinetics of metallurgical One describes the kinetics of metallurgical One describes The kinetics of metallurgical processes,

270


processes. The molten metal phases. Diffusion processes in the alloys. Thermodynamics of formation of the dissociation of oxides, chlorides, fluorides, sulfides, carbonates and silicates.

The oxidation in the gas phase. Interaction of the alloy with furnace lining. The interaction of metal with melted slag. Reacting the metal with carbon. Melted slag and their role in metallurgical smelting processes.

processes, the molten metal phases, diffusion processes in the alloys, and thermodynamics of formation.

the molten metal phases, diffusion processes in the alloys, and thermodynamics of formation. One names interaction of the alloy with furnace lining, melted slag, carbon, a role of melted slag in metallurgical smelting processes.

Topic 20. Characteristics of processing foundry alloys in the liquid state

Physical properties of melted slag. Basic and acidic wastes. Interaction of melted slag with lining furnace. Molecular and ion theory of the slag. Processing casting alloys in liquid state. Refining, deoxidation, removal of non-metallic inclusions.

One characterizes the processing of foundry alloys in liquid state.

One names physical properties of melted slag, interaction of melted slag with lining furnace. One judges on molecular and ion theory of the slag and describes processing casting alloys in liquid state.

271


Analysis of secondary treatment.

Topic 21. The classification of iron smelting processes

Cast iron smelting process, the general provisions. Thermodynamics o melt smelting processes. Oxidation and reduction of elements in the process of smelting cast iron. Physical and chemical bases of modifying cast iron. Analysis of melting units and processes of smelting cast iron.

The classification of iron smelting processes One describes thermodynamics o melt smelting processes, physical and chemical bases of modifying cast iron.

Topic 22. Charging materials, ferroalloys, fluxes

Charging materials. Foundry pig iron. Blast furnace iron and foundry pig iron. Cast iron and steel scrap and waste of ferrous metals. Ferroalloys, modifiers, fluxes, carburizing. The calculation of the charging materials.

One describes charging materials, foundry pig iron, blast furnace iron and foundry pig iron, ferroalloys, modifiers, fluxes, carburizing.

One describes charging materials, foundry pig iron, blast furnace iron and foundry pig iron, ferroalloys, modifiers, fluxes, carburizing. One explains the calculation of the charging materials

272


Topic 23. Fuel used in melting aggregates

Cupola solid fuel. Foundry coke, coke briquettes, anthracite and thermo-anthracite, charcoal, cast calcium carbide. The liquid fuel or gaseous fuel.

One characterizes fuel used in melting aggregates.

One describes cupola solid fuel, foundry coke, coke briquettes, anthracite and thermo-anthracite, charcoal, cast calcium carbide, the liquid fuel or gaseous fuel.

Topic 24. Smelting iron in cupola furnaces

The theory of cupola process. The main types of modern cupola. Changes in the composition and temperature of the gases over the cross section and the height of the cupola. The zones of cupola. Changing the chemical composition of the iron in the melting process. Factors affecting the degree of carbonization and the increase in the sulfur content of the iron. Cupola furnace slag, its formation and the influence on the process of melting and lining.

One describes changing the chemical composition of the iron in the melting process, factors affecting the degree of carbonization and the increase in the sulfur content of the iron, intensification of heat processes, and optimization of heat processes.

One names types of modern cupola. One describes changing the chemical composition of the iron in the melting process, factors affecting the degree of carbonization and the increase in the sulfur content of the iron, intensification of heat processes, and optimization of heat processes.

273


The transition of melting from the one charge stock to another one. The use of cast iron and steel-term chip in smelting iron in a cupola. Intensification of heat processes. Optimization of heat processes. Duplex smelting of cast iron.


The study of cast iron melting in the cupolas.

One analyses processes of cast iron melting in the cupolas.

One analyses processes of cast iron melting in the cupolas.

Topic 25. Features of acidic and basic processes of smelting iron in a cupola furnace

The features of acidic process of iron smelting in the cupola. The features of the main process. Acidic and basic lining materials. Acidic and basic melted slag. Physical and chemical processes of interaction of liquid slag and lining materials.

One names the features of acidic process of iron smelting in the cupola.

One names the features of acidic process of iron smelting in the cupola and describes Acidic and basic lining materials, melted slag, physical and chemical processes of interaction.

274


Topic 26. Melting of cast iron of different grades

The features of cast iron smelting of various grades. Recommendations for the use of the raw materials. Melting of modified cast iron. Methods for modification of cast iron. The amount of the administered modifiers and methods for their introduction into the molten iron. Melting of alloyed cast iron. The features of casting.

One names features of cast iron smelting of various grades.

One names features of cast iron smelting of various grades. One develops methods for modification of cast iron and describes melting of modified cast iron.

Topic 27. Melting of cast iron in electric melting units

Melting in electric arc furnaces, the main types of melting units. Smelting iron in induction furnaces, the main types of the applied melting units, scope, the features of the melting process. Technology in induction melting furnaces. The use of electric melting units in duplex and

One names types of melting units, application scope and features of the melting process.

One names types of melting units, the scope, the features of the melting process. One describes technology of melting in electric arc furnaces and in induction melting furnaces.

275


triplex smelting processes.

Topic 28. Heat of steel in electric arc furnaces

Modern processes for the production of steel. Thermodynamics of processes. Physical and chemical characteristics of the smelting process of steel. The scope of acidic and basic arc furnaces. Charging materials for acidic and basic processes. Technological features of melting. The basic process. Removal of sulfur and phosphorus. Variations of the process. Deoxidation under white and carbide melted slag. The sour process, advantages and disadvantages. Technical and economic parameters of the process.

One characterizes the methods of smelting steel in electric arc furnaces.

One describes thermodynamics of processes, physical and chemical characteristics of the smelting process of steel. One names the scope of acidic and basic arc furnaces, charging materials. One explains technological features of melting, variations of the process, advantages and disadvantages, technical and economic parameters of the process.


276


The study of steel melting in an electric arc furnace.

One analyses steel melting in an electric arc furnace.

One analyses steel melting in an electric arc furnace.

Topic 29. Heat of steel in induction furnace units

The application of induction furnaces. Technological features of melting. Charging materials. The advantages and disadvantages of the melting process in the induction melting units. Technical and economic parameters of the process.

One characterizes technological features, the advantages and disadvantages, technical and economic parameters of the process of melting in an induction furnace unit.

One names application of induction furnaces, charging materials. One describes technological features, the advantages and disadvantages, technical and economic parameters of the process.


The study of steel melting in induction furnace units.

One recreates steel melting process in an induction furnace unit.

One analyses steel melting process in induction furnace units.

Topic 30. Preparation of steel of high quality

The electroslag remelting process. The concept of electroslag casting (ESC). The features of interaction of phases and physical-chemical

One describes melting in plasma and vacuum furnaces, the electron beam melting, installation diagram and the principle of operation, the application area.

One judges on the ESC. One describes melting in plasma and vacuum furnaces, the electron beam melting, installation diagram and the principle of operation, the application area.

277


characteristics of ESC. Melting in plasma furnaces, installation diagram and functions. Melting in vacuum furnaces. The melting process. Application area. The electron beam melting. The principle of operation. The quality of metal. Optimization of heat processes.

Control work

Topic 31. Melting of aluminum and magnesium alloys

General characteristics of the smelting of non-ferrous alloys. The development of processes of melting of non-ferrous metals and alloys. Role of refining. The furnaces used for melting of aluminum alloys. The features of production processes of aluminum alloys. Preparation of master alloys, fluxes. Technological features of

One characterizes melting of aluminum and magnesium alloys.

One describes characteristics of the smelting of non-ferrous alloys, furnaces, used for melting of aluminum and magnesium alloys, the features of production processes of alloys. One explains technological features of melting and casting.

278


melting and casting. Degassing and removal of non-metallic inclusions.

Melting of magnesium alloys. General provisions of melting. Charging materials. The peculiarities of magnesium alloys. Preparation of master alloys and advanced alloys. Refining. Covering and degassing fluxes. The features of casting. Safety requirements and safety during the melting of magnesium alloys.

Topic 32. Melting of copper and nickel alloys

General provisions of melting. The furnaces used for melting of copper alloys. Ligatures, the composition of fluxes and reductants. Refining and degassing of copper alloys. Melting of tin bronzes. Melting

One characterizes special features of the process of melting of copper and nickel alloys.

One names furnaces, used for melting of copper and nickel alloys, charging materials and fluxes. One describes melting of tin bronzes, yellow metal, nickel alloys. One shows the features of melting and casting.

279


of yellow metal. Melting of nickel alloys. The furnaces used for melting of nickel alloys. Charging materials and fluxes. The features of melting and casting.

Topic 33. Melting of lead and zinc alloys

Grades and chemical composition of zinc alloys. Physical and chemical properties of melting processes. The furnaces used for melting of zinc alloys. Impurities and their influence on the properties of zinc. Refining zinc alloys. Technological features of melting and casting of zinc alloys.

Melting of lead alloys. Physical and chemical properties of the smelting processes. Furnaces used for melting lead alloys.

One characterizes special technological features of melting of lead and zinc alloys.

One describes grades and chemical composition of zinc alloys, physical and chemical properties of melting processes. One names the furnaces used for melting of zinc and lead alloys. One develops technological features of melting and casting of lead alloys.

280


Technological features of melting and casting of lead alloys. The properties of alloys based on lead.

281

Guidelines

The following forms of organization of teaching are recommended in order to implement a training program on discipline “Casting alloys and melting process”: lectures, workshops, field trips, laboratory classes.




– teaching students for analysis of the structure and properties of the alloys;- study of casting, mechanical and performance properties of the iron-carbon

and non-ferrous metals and alloys, their fields of application.Discipline “Casting alloys and melting process” is based on the knowledge

gained from studying such disciplines as “Chemistry”, “Physics”.

The knowledge gained from the study of the unit used in the study of following units:

- Theory and technology of foundry production;

- Design of tooling.

In the study the unit it is required to carry out integration with the academic disciplines of general professional and special cycles.

The control of this academic discipline includes interim assessment, basic forms of which are the following: assessment papers, credits, and tests.

The implementation of this syllabus provides for carrying out the following:

- Intermediate assessment papers - 2;

- Credits - 2.


282


A study of academic disciplines a student must know:

- modern concept of the structure and properties of metal melts;

- patterns of crystallization of alloys, methods of assessment;

- relationship of state diagrams of the nature of crystallization, structure and casting properties of alloys;

- types of heat treatment alloys;

- the used equipment and physical and chemical bases of melting processes;

- casting, physical, mechanical and performance properties iron-carbon and non-ferrous metals and alloys, their field of application.

A student must be able to:

- use state diagrams to describe the nature of the alloy solidification of castings, their structure and properties of casting;

- determine the characteristics of casting alloys by experiment or calculation;

- determine the mode of heat treatment alloys;

- carry out an effective range of melting equipment, modes and parameters of melting for specific types of alloys;

- analyze the causes of the defects at the casting and to develop ways to eliminate them;

- perform the calculation of the required composition of the charging material;

- choose the alloy for specific details with regard to the conditions of its operation.

283

DESIGN AND TECHNOLOGICAL BASIS FOR THE PRODUCTION OF MOULDS FOR MANUAL MOLDING

The purpose of the discipline is to develop the students' knowledge in the structure and properties of cores and their manually fabrication process.


Topic

Number of hours

all

including

laboratory works

practical works

Introduction 1

1. Basic processing methods used in the manual production of cores

7 2 2

2. Typical recipes of core sand mixtures used for manual molding cores

7 2 2

3. Methods of control of technological properties of core sand mixtures

4 2

Control work 1

4. Working conditions of cores and basic requirements to them

2

Total 22 4 6

284



Introduction

The structure and content of the course “Design and technological basis for the production of moulds for manual molding”. The goals and objectives of the discipline. The role of the unit in the formation of professional knowledge, skills of students. The prospects of development of cores production while hand molding.

One expresses an overall judgment of the content of the subject “Design and technological basis for the production of moulds for manual molding”, goals, objectives and role of the unit in the formation of professional knowledge and skills.

One expresses an overall judgment on the content of the subject “Design and technological basis for the production of moulds for manual molding”, on goals, objectives and role of the unit in the formation of professional knowledge and skills. One calls the development of prospects of production of cores while manual molding.

Topic 1. Basic processing methods used in the manual production of cores

Processing methods of manufacturing standard castings. The main stages of development of the technology of manufacturing molds. The methods for hand molding. The configuration and dimensions of the casting. The number and configuration of mold and pattern opening area. Foundry pattern tapers. Detachable parts of the model. Application of cores. The way of installation, supply and assembly of cores. Construction of casts in terms of conditions of filling the mold with metal.

One expounds basic processing methods used in the manual production of cores.

One describes and composes technological methods of manufacturing standard castings. One classifies hand molding techniques and specifies the number, quality and foundry pattern tapers. One can interpret drawings of castings.

285


Walls thickness of the cast. Fit of walls, corners and tides. Hot spots.

Practical work No. 1

The study of technological methods of producing castings in sand-clay forms.

One analyzes and carries out technological methods of producing castings in sand-clay forms.

One analyzes and composes technological methods of producing castings in sand-clay forms.


The study of the principles of designing the mold. One analyzes and provides justification for the principles of designing the mold.

One analyzes and justifies the principles of designing the mold.

Topic 2. Typical recipes of core sand mixtures used for manual molding cores

Formulations of core sand mixtures. The appointment of the character contour of the cores. Fixation of cores in the mold. The calculation of the construction of a sign. The methods of calculating profits. Determining the location of profits.

One expounds typical recipes of core sand mixtures used for manual core molding.

One unfolds the recipes of core sand mixtures and explains the character contour of the cores, locking cores in the molding. One describes the methods of calculating profits.


The study of design principles of molding cores. Designing molding cores. One substantiates the principles of designing cores.

286



The study of design of the sign and the calculation of profits.

One researches sign construction and profit calculation.

One analyzes construction sign and settles profits.

Topic 3. Methods of control of technological properties of core sand mixtures

Humidity control of materials and mixtures, of green bond or dry bond, gas permeability. Determination of the content of clay in the molding sand. Determination of grain composition. Types of defects. Causes of defects and measures to prevent them.

One describes methods of control of technological properties of core sand mixtures.

One explains types of humidity control of the materials and mixtures, of green bond or dry bond, gas permeability. One specifies the content of clay in the molding sand, and grain composition and describes the types and causes of defects.

Control work


Determination of the defects in the castings of ferrous alloys.

One determines the moisture level of mixtures and materials.

One determines the defects in the castings of ferrous alloys.

Topic 4. Working conditions of cores and basic requirements to them

The requirements for the cores. Determination of compliance with the requirements on such indicators as the strength, the pressure of the liquid metal, gas

One explains the requirements on such indicators as strength, pressure of liquid metal, gas permeability,

One describes the requirements for the cores and determines the compliance with the requirements on

287


permeability, yielding, fire resistance. yielding, and fire resistance. such indicators as the strength, the pressure of the liquid metal, gas permeability, yielding, and fire resistance.

288

Guidelines

The following forms of organization of teaching are recommended in order to implement a training program on discipline “Construction and technological bases of hand molding cores”: lectures, workshops, field trips, laboratory classes.



This educational program includes teaching students the analysis of structure and properties of cores.

The discipline Design and technological basis for the production of moulds for manual molding” is based on the knowledge gained in the study of educational discipline “Casting alloys and melting process”.

The control of this academic discipline provides interim attestation the main forms of which are assessment paper, credits and tests.

In implementing the syllabus the following forms of attestation are provided for:

- assessment paper - 1;

- credit- 1;

Educational organizations implementing the education program should develop competence-oriented tasks in the form of a test.

Tests should be presented by sections, topics and have three basic difficulty levels (low, medium and hard).

The knowledge gained from the study of the discipline is used in the study of the following discipline:

- Theory and technology foundry production


- Design and technological bases of machine production cores.

289

In the study of the discipline it is necessary to carry out the integration with the educational-disciplines of general professional and special cycles.

As a result of study of the academic discipline a student must know:

- major technological methods used in hand molding cores;

- typical recipes of core sand mixtures used for hand molding cores;

- methods of control of technological properties of core sand mixtures;

- working conditions of cores and basic requirements for them;

a student must be able to:

- monitor the quality and condition of the core sand mixtures and core boxes;

- produce cores with detachable parts, frames and frames

- manufacture ceramic cores for castings from special steels;

- produce cores from free-running, self-hardening and cold-hardening sand mixtures;

- select the cores for drying.

290

ECONOMICS, ORGANISATION AND PLANNING OF PRODUCTION

The purpose of the study of the discipline is formation of students' knowledge of basic economic concepts of the market, the essence of the organization of productive assets, the foundations of the organization of wages, profit planning and cost jobs.

The role and importance of the discipline in the preparation of competitive staff is development of entrepreneurial abilities of students, the ability to navigate the complexity of market-governmental relations, social adaptation of students.


Section, Topic

Number of hours

all

Including hours for laboratory

works

1 2 3

Introduction 1

Section 1. Fundamentals of market economy 7

1.1. Market mechanisms and principles of its functioning 1

1.2. The essence of the taxes and the tax system of the Republic of Kazakhstan

2

1.3. State regulation of the financial system 2

1.4. Features of organizations of different ownership forms 2

Section 2. The production organization's resources 8 4

2.1. Fixed assets of the organization 6 4

2.2. Working capital of the organization 2

Section 3. Organization of production 12 4

291

1 2 3

3.1. Organizational bases of production 2

3.2. Organization of flow-line and automated production 4 2

3.3. Organization of auxiliary shops and catering services of an entity

1

Control work 1

3.4. Organization of payments for labor. Forms of payment in organizations of different ownership forms

4 2

Total 28 8

Section 4. Planning production 20 2

4.1. Credit systems and banks 2

4.2. Organization of the industry in the system of market relations 2

4.3. Basics of planning. A business plan of a company 2

4.4. Logistics planning 2

4.5. Layout of work and wages planning 2

4.6. Cost planning 2

4.7. Planning for the technical development of the organization 1

4.8. The plan to improve production efficiency 5 2

4.9. Operational and production planning 2

Section 5. Accounting, reporting and analysis of the production activity of organizations in market conditions

5

5.1. Accounting and reporting of the organization 2

5.2. Analysis of production and economic activities of the organization in the marketplace

2

Control work 1

Section 6. Development of the organization (manufacturing) 3

292

1 2 3

6.1. Innovations and innovative activities of the company 1

6.2. Marketing of innovations 2

Course project 24

Total 52 2

In all 80 10

293



Introduction

The objectives and content of the discipline “Economics, organisation and planning of production”. The role of the discipline in the formation of professional knowledge and skills. The relationship with other academic disciplines.

The current state of the economy of the Republic of Kazakhstan. The need for active structural policies, setting priorities: Energy and Steel and metal complexes, industries in the consumer sector, communications.The anti-crisis and anti-monopoly program, the deepening of social and economic reforms, stimulating tax policy.

One provides general judgment on the contents of the discipline “Economics, organisation and planning of production”, the role of the discipline in the formation of professional knowledge and skills.

One gives general judgment on the contents of the discipline “Economics, organisation and planning of production”, the role of the discipline in the formation of professional knowledge and skills, the relationship with other academic disciplines, the current state of the e

conomy of the Republic of Kazakhstan.

Section 1. Fundamentals of market economy

Topic 1.1. Market mechanisms and principles of its functioning

The essence, functions and structure of One describes the essence, functions One develops the essence, functions and


the market. The subjects and infrastructure of market economics.The market mechanism. The theory of supply and demand. The equilibrium price.The market of consumer goods and services. Currency and equity markets.The market of information, intellectual products and innovation. The innovative process under market conditions and its stages.The labor market, the market infrastructure, the mechanism of social security (unemployment benefits, the official definition of poverty, income indexing, etc.). Employment Service.Exchange. Exchange transactions. Logistics. Types of exchanges. The functions of an exchange.The occurrence, nature and function of money. The law of monetary circulation. The problem of stability and convertibility of money.Forms and methods of stabilizing the currency.

and structure of the market.

One expounds market mechanisms and the foundation of its functioning.

structure of the market, describes market mechanism and types of market. One explains the occurrence, nature and function of money and names forms and methods of stabilizing the currency.

Topic 1.2. The essence of the taxes and the tax system of the Republic of Kazakhstan

The tax system of the Republic of One expounds the essence of taxes and One describes tax system of the Republic of

295


Kazakhstan. The Tax Code of the Republic of Kazakhstan. The principles of taxation. Functions of the taxes. Tax rates. The elements of the tax and its collection methods. Direct and indirect taxes.

taxing system of the Republic of Kazakhstan.

Kazakhstan. One follows the Tax Code of the Republic of Kazakhstan and explains the principles and functions of taxation.

Topic 1.3. Features of organizations of different ownership forms

The essence, structure and functions of finance. The state budget is the main link in the financial system. Finance of state organizations. Local finance.

One describes government regulation of the financial system.

One describes the essence, structure and functions of finance. One explains the concept of state budget and finance.

Topic 1.4. Features of organizations of different ownership forms

The features, the main terms, the order of creation and organization of production and economic activities of organizations in a market economy.Partnership. Joint-stock companies. Public organizations and their role in the economy of the Republic of Kazakhstan.The procedure for the management of public organizations of various categories.

One expounds special features of activities of organizations with different forms of ownership.

One tells the features, the main terms, the order of creation and organization of production and economic activities of organizations in a market economy.One names the procedure for the management of public organizations of various categories.One describes the organization of economic and social activity of the state of organization.

296


Saving the regulatory role of the state in the transition period.The organization of economic and social activity of the state of organization, rental, private, cooperative ones and others. The economic responsibility for its results.

Section 2. The production organization's resources

Topic 2.1. Fixed assets of the organizationProduction assets of the organization, their composition. Fixed assets, their economic essence, and classification. The structure of the main production-governmental funds in the volume and value terms. The methods of calculating the average annual value of fixed assets. The types of depreciation of fixed assets.Depreciation and amortization of fixed assets. Methods of calculating depreciation on the full restoration of basic production assets.Performance indicators of fixed assets and their value.

One expounds the essence of fixed assets of an organization.

One shows the economic essence the main production-governmental funds, describes their structure, composition. Ones describes depreciation and amortization of fixed assets, performance indicators of fixed assets and their value. One reveals. One finds out the directions of improving the utilization of fixed assets.

Practical work No.1Calculation of the use of fixed assets, their average cost, and depreciation

Calculation of the use of fixed assets, their average cost, and depreciation

One calculates indexes of the use of fixed assets, their average cost, depreciation cost.

297


cost. cost.Topic 2.2. Working capital of the organization

Working capital of the organization, their composition and structure. Rationing of circulating assets. The circuit performance and turnover of working capital. The relationship of efficiency of use of production assets and outcomes of the organization.Calculation of return on assets, the capital ratio, coefficient of extensive and in-use integrated intensity of ratios of coefficients of shifts.The calculation of depreciation on the full restoration. The calculation of the basic structure of the pro-production assets. The calculation of the norm of working capital. Calculation of the sum, freed up from working capital as a result of acceleration of their turnover.

One expounds the working capital of an organization.

One names the composition and the structure of the current assets of the organization. One explains the methodology for calculating the indicators of return on assets, depreciation amounts, the structure of the fixed assets, the standard of the working capital.

Section 3. Organization of productionTopic 3.1. Organizational bases of production

The labor process: a stage, an operation, a working method, a labor action.

One describes the process of labor. One describes the labor process. One describes the essence and meaning of technical regulation.

298


The methods of rationalization of labor movements and planning requirements for jobs places. Technical regulation, its essence and meaning.

Topic 3.2. Organization of flow-line and automated production

Fundamentals of the organization of flow-line and automated production. General characteristics of the flow-line production. The cycle of the production line. Classification of major species of production line. The features of the organization of continuous flow lines (CFL). Synchronization. Basic calculations of CFL (process stock). The features of the organization of continuous flow lines. Calculation of interoperable current process stocks. The features of multi-disciplinary organization of production lines.

The automation of flow line production. Types of automatic lines. Types and kinds of the organizational and technical

One characterizes the special features of the organization of flow-line production.

One explains fundamentals of the organization of flow-line and automated production. One names the features of the organization of multidisciplinary continuous flow lines (CFL), types and kinds of the organizational and technical features of the establishment and operation of the automated lines. One explains calculation of interoperable current process stocks features of the organization.

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features of the establishment and operation of the automated lines.

Practical work No.2

Calculation of interoperable current process stocks. Calculation of enlarged beat (rhythm) of production line.

Calculation of interoperable current process stocks. Calculation of enlarged beat (rhythm) of production line.

One performs calculation of interoperable current process stocks and calculation of enlarged beat (rhythm) of production line.

Topic 3.3. Organization of auxiliary shops and catering services of an entity

The goals and objectives of the auxiliary shops and catering services of the organization. The organization of maintenance services of the entity. The organization of energy services. The organization of the transport and storage sector. The logistics organization in the entity. The production capacity of the organization.

One describes the organization of auxiliary shops and catering services of an entity.

One gives general judgment on goals and objectives of the auxiliary shops and catering services of the organization. One explains the features of the organization of maintenance, energy, transport, storage services and characterizes logistics organization in the entity.

Control work

Topic 3.4. Organization of payments for labor. Forms of payment in organizations of different ownership formsLabor legislation in the field of remuneration. The objectives and principles of the organization of wages.

One explains the essence of wages, principles of the organization of wages, describes forms and systems of

One explains the essence of wages, principles of the organization of wages, describes forms and systems of wages, their

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Tariff system and its elements. The conditions and performance of bonuses. The mechanism of social protection of employees of various forms of ownership.There are straight-time rate, time-bonus rate, straight piece rate, job rate with bonus, piecework progressive wages and accord wages.Methods for determining the rates and costs in the organizations of various forms of liability sob. Methods of distribution of payroll budget.

wages, their peculiarities. peculiarities. One describes the methods of determining rates and costs in the organizations of various forms of ownership.

Practical work No.3

Calculation of the total payroll budget, average wages, deductions from the payroll budget.

Calculation of the payroll budget, average wages, and deductions from the payroll budget.

One can calculate the payroll budget, average wages, and deductions from the payroll budget.

Section 4. Planning production

Topic 4.1. Credit system and banksCredit banking system. The types and forms of credit.Credit and banking institutions. Leasing, factoring, financial and trust operations.

One describes banking credit system. One judges on credit banking system and describes the types and forms of credit.

Topic 4.2. Organization of the industry in the system of market relations

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The concept of the organization as a key component of the economy of the Republic of Kazakhstan. Types of activities. The charter and passport organizations. The procedure of establishing a new organization. The production structure of the organization (management, production sites, jobs). The essence and the advantages of franchising.

One describes types of activities and the procedure of establishing a new organization.

One unfolds the concept of the organization as a key component of the economy. One describes types of activities, the procedure of establishing a new organization, explains the essence and the advantages of franchising.

Topic 4.3. Basics of planning. A business plan of a company

Types of plans. The organization of planning in the entities in the market conditions. The procedure for developing a business plan for the organization, its sections and their brief characteristics.Perspective and current planning. The strategic plan of development of Kazakhstan “Kazakhstan-2050”.

One expounds types of plans, procedure and sections of developing an organization’s business plan.

One names the types of plans and describes the procedure of developing a business plan for the organization and its chapters. One sets out the main provisions of the Strategic Plan of Development of Kazakhstan “Kazakhstan-2050”.

Topic 4.4. Logistics planningThe essence and objectives of logistics planning. Technical and operational rates and the stock of material resources. The procedure for planning and calculation of the organization's needs for material resources in volume

One describes planning the logistics of an organization.

One unfolds the essence and objectives of logistics planning. One explains the procedure for planning and calculation of the organization's needs for material resources in volume and value terms, the

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and value terms. The ways of saving and rational use.

ways of saving and rational use.

Topic 4.5. Layout of work and wages planning

The content of the plan for labor and human resources, its relationship with other sections of the annual plan, the initial data for its preparation. Categories of workers in the organization. Planning of the number of industrial personnel. Methods of planning of the number of workers.The concept of productivity. Method of calculation of duration of labor. Ways to increase labor productivity.The concept of the payroll. Methods of planning time, daily, monthly, annual payroll budget. Primary and secondary wage fund. Methods of calculating the salary fund of time-workers and piece workers. The calculation of average wages. The calculation of the ratio of the rate of growth of wages and productivity. Deductions from wages fund.The calculation of states and salaries of the employees of individual divisions. Calculation of planned productivity and

One expounds the methods of calculating the planning of the layout of work and wages provision.

One names content of the plan for labor and human resources, composition and structure of workforce of the organization.

One unfolds the method of calculation of duration of labor, ways to increase labor productivity.

One describes the calculation of average wages, the calculation of the ratio of the rate of growth of wages and productivity.

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average wages. The calculation of deductions from the payroll budget.

Topic 4.6. Cost planning

The concept of cost and its value as an important indicator of economic activity of the organization. The cost structure and the ways to reduce it. Plan of costs. Cost estimates and calculation.

Calculation of cost estimates of manufacturing products, works and services. Calculation of costs for products, works and services (for the organization as a whole, individual production of structural units and certain types of products).

One describes the system of planning a product’s prime cost.

One describes the cost structure and the ways to reduce it. One explains calculation of cost estimates of manufacturing products, works and services, calculation of costs for products, works and services (for the organization as a whole, individual production of structural units and certain types of products).

Topic 4.7. Planning for the technical development of the organizationThe main points of individual process in the marketplace. Plan of the technical development of the organization, content and measures to improve production efficiency. Planning for innovations in the operation and repair

One expounds the basics of planning of the technical development of an organization.

One unfolds the main points of individual process in the marketplace. One describes planning for innovations in the operation and repair of equipment.

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of equipment.

Topic 4.8. The plan to improve production efficiencyThe procedure for drawing up a plan to improve production efficiency. The total (absolute), and comparative cost-effectiveness. The system of indicators to improve production efficiency.The calculation of the economic efficiency of new equipment investment. The calculation of the economic efficiency of organizational and technical measures.

One characterizes the plan of improving production efficiency.

One names the procedure for drawing up a plan to improve production efficiency and explains the total (absolute), and comparative cost-effectiveness, the system of indicators to improve production efficiency, the calculation of the economic efficiency of new equipment investment, the calculation of the economic efficiency of organizational and technical measures.

Practical work No.4

The calculation of the economic efficiency of the implementation of new technology and investment.

The calculation of economic efficiency of implementing new technology and investing capital.

One calculates the economic efficiency of the implementation of new technology and investment.

Topic 4.9. Operational and production planning

The content, significance and objectives of operational and production planning. The forms and methods of operational planning. The meaning of smooth operation of the organization, the department, the section. The

One expounds the content, significance and objectives of operational and production planning.

One unfolds content, significance and objectives of operational and production planning and characterizes the forms and methods of operational planning.

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organization of shift-day planning of the company, teams, departments, sections. Background and procedure for the development of an operational plan.

Section 5. Accounting, reporting and analysis of the production activity of organizations in market conditions

Topic 5.1. Accounting and reporting of the organization

The accounting of the organization in foundry production. The concept of economic accounting. Types of records, their nature, objectives and the relationship. The increasing role of accounting in the market. The accounting records. Document Classification (unified and specialized). Cumulative statement, payment card. The relation of reporting of the organization with statistics.Types of records, their nature, objectives and the relationship. The increasing role of accounting in the market. Documentation: pay-in slips, invoices, claims. The records of write-offs acts. Inventory books, inventories. Card inventory accounting. Sheet delivery products. The accounts for the

The knowledge of the features of accounting and recording in an organization.

One characterizes the accounting and reporting of the organization in foundry production, describes types of records, their nature, objectives and the relationship. One explains the records of write-offs acts, inventory books, inventories, card inventory accounting, sheet delivery products, the accounts for the shipment of the finished products, of accounting work and wages.

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shipment of the finished products. The objectives of accounting work and wages. Accounting personnel working hours. Making reception, holidays, layoffs. Personal cards, employment records, timesheets. Accounting for production of output and wages.The report on the costs of production.

Topic 5.2. Analysis of production and economic activities of the organization in the marketplace

The goals and objectives of the economic analysis of economic activity. Initial data for analysis of their relationship, validation of accounting data.The methods of analysis of economic activities. The direct supply of securities accounts and other forms of analytical approach to the assessment of the organization. The role of economic analysis in the search for reserves to enhance production efficiency.The essence of the analysis of the implementation of the production plan, the initial data. Overall assessment of the plan. Analysis of factors affecting the volume of production, works and

One expounds the methods of analysis of production and economic activities of an organization on the market.

One unfolds the goals and objectives of the economic analysis of economic activity, describes the methods of analysis of economic activities, judges on the availability of organization of labor, use of labor.

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services. Analysis of rhythmic production during the study period. The study of the growth of reserves in production through better use of the fixed assets, the working capital, the labor force. Analysis of the availability of organization of labor, use of labor.

Control work

Section 6. Development of the organization (manufacturing)

Topic 6.1. Innovations and innovative activities of the company

The innovation: concept and types. Innovative activity. Characteristics of the innovation process, the content of its stages.

Innovative projects: basis, methods and criteria for selecting the most effective. High-tech projects: concept, basis and methods of selection for investment. Intellectual and industrial property: the notion and use efficiency.

Formation of innovative strategy. The impact of innovation on

One describes the state regulation of innovation and planning for innovation in the organization.

One gives general judgment on economic essence of the innovations and innovative activity.

One describes the state regulation of innovation and planning for innovation in the organization.

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competitiveness strategy of the organization of production and competitiveness of the organization. Problems of ensuring the effectiveness of innovation.

The state regulation of innovation. Planning for innovation in the organization. High-tech products and the features of its market promotion.

Topic 6.2. Marketing of innovations

The principles of marketing innovation and its basic concepts. The stages of development of a new product and the life cycle in the market. The organization of marketing service in innovation-driven companies. Innovation and modern marketing concept. The development of new product marketing unit: sales and service. Planning and management of the innovations.

One expounds the essence of marketing of innovations.

One unfolds principles of marketing innovation and its basic concepts, describes the stages of development of a new product and the life cycle in the market and planning and management of the innovations.

Course project

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A course work includes the following sections:

An introductory clause. An estimated part.

Calculation of the number of production workers, the calculation of the fund earned payment, calculation of the cost of materials and spare parts, design estimates.

Summary and Conclusions.

Course work. One proves the economic decisions of organizational and technical tasks in the foundry industry. One performs calculation of technical and economic parameters of the process foundry.

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Guidelines

The following forms of organization of teaching are recommended in order to implement a training program on discipline “Economics, industrial management and planning”: lectures, workshops, field trips, laboratory classes.



Discipline “Economics, industrial management and planning” is based on the knowledge gained from studying such disciplines as:

– Mathematics

– Law Basics.

This training program provides practical training, which contribute to more successful mastering of educational material, getting the hang of solving practical problems, for example, the definition of indicators of production fund use, the calculation of wages paid workers, various forms of remuneration, the calculation of cost estimates and costing of works.

The control of this academic discipline provides interim attestation the main forms of which are assessment paper, course work, tests and credits.



- course work -1;

- credits- 2;


Tests should be presented by sections, topics and have three basic difficulty levels (low, medium and hard) for each level of professional qualification.

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- the composition and structure of economic system of the state;

- objectives and motives of the production organizations, their classification and structure;

- tasks, forms, business sectors;

- finance organization, financial resources, profit and gross income structure;

- the organization of wages, composition and structure of the production staff of a company;

- the mechanism of the company management;

- planning activities of the organization;

--internal economic relations;

- organization and planning of innovation;

- control of the quality and competitiveness of products;

- investment activities of the organization;

- assessment of the effectiveness of the organization's activities: indicators, calculation methods, the scope of application;

A student must be able to:

- analyze economic phenomena and processes taking place in the organizations of foundry and metallurgical complex;

- taking industrial and administrative decisions in order to achieve maximum results in the organization of casting and metallurgy complex;

- plan the organization's activities;

- master new forms of innovation and entrepreneurship.

The knowledge gained in the study of the discipline must be secured and deepened in the process of performance of course work.

A course work is independent work of students and is based on factual data. Theoretical provisions of the situation is necessary to be reinforced by the analysis of the existing practice.

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By the content the course work has a research character. The course work must meet the following requirements:

1) the course work must be performed on actual topic of practical importance according to the reasonable plan;

2) course work should be written on the basis of deep study of legislation on the problem, as well as monographs and articles on the subject of the chosen topic;

3) the course work should indicate that its author knows modern, wide theoretical and methodological foundations of the economy of the organization;

4) the course work must indicate that the author is able to work with literary sources: to find the necessary material, to analyze point of view of the various authors, and relied on the analysis to give the assessment and to formulate proper conclusions;

5) the course work should include: elements of analysis of factual material on the economic activities of organizations, the comparison of the requirements of theory and factual states in the economies of the organizations, founded conclusions and specific proposals;

6) the course work shall be executed in strict accordance with the requirements.

Compliance with these requirements is a criterion for the assessment of the course work.

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SAFETY AND HEALTH MANAGEMENT

The purpose of the discipline is the study of issue of security and work safety, the development of measures on safety and health in the workplaces.


Section, Topic

Number of hours

all

including

laboratory

works

practical

works

1 2 3 4

Introduction 2

Section 1. The requirements of labor protection and work safety

8 4

1.1. The requirements of labor protection and work safety in the legislation of the Republic of Kazakhstan

2

1.2. Management of labor protection 6 4

Section 2. Improving the efficiency of the work on labor protection and work safety

6 2

2.1. Evaluating the effectiveness of safety management system

2

2.2. Recording and investigation of accidents 4 2

Section 3. Fire safety basics 8 2 2

3.1. Fire safety requirements 2

Control work № 1 1

3.2. Securing an object against fire 5 2 2

Total 24 2 8

314

1 2 3 4

Section 4. General hygiene requirements for the production facilities and jobs

24 2 6

4.1 General occupational hygiene, assessment of working conditions

2

4.2. Normalization of working conditions and sanitary maintenance of manufacture

4

4.3. The microclimate and ventilation facilities 6 2 2

4.4. Protection against noise and vibration 6 2

4.5. Protection from exposure of industrial dust 2

4.6. Lighting of production facilities 4 2

Section 5. Legal and organizational issues of security and safety

24 4

5.1. Safety of technological equipment 4

5.2. Process safety 4

5.3. Protection from exposure of production radiation sources 2

5.4. Basics of electrical safety 6 2

5.5. Hazardous and harmful industrial chemical factors 6 2

Control work № 2 1

5.6. Organization of fire protection in the industry 1

Total 48 2 10

Total 72 4 18

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Introduction

The structure and the content of the discipline “Safety and health management”. The goals and objectives of the discipline, the relationship with other academic disciplines. The role of the unit in the formation of professional knowledge, skills.

International cooperation in matters of labor protection and work safety. Basic terms and definitions.

Positive and negative effects of scientific and technological progress in the working conditions and environment.

Advanced manufacturing experience, research work, rationalization and invention on labor protection and work safety.

One expresses an overall judgment on the content of the educational discipline “Safety and health management”, the role of the discipline in the formation of professional knowledge and skills, connections to other academic disciplines.

One expresses an overall judgment on the content of the educational discipline “Safety and health management”, the role of the discipline in the formation of professional knowledge and skills, the relationship with other academic disciplines.

Section 1. The requirements of labor protection and work safety

Topic 1.1. The requirements of labor protection and work safety in the legislation of the Republic of Kazakhstan

Labor law and its basic principles. Fundamentals One expounds labor protection and One expresses general judgments

316


and sources of labor law.

Forms and content of regulatory legal acts on occupational safety and health. Normative legal acts of functional government (ministries, departments, etc.) to ensure the implementation of the right to work and security. Technical and legal rules and regulations of labor protection and work safety, their types, purpose, scope, procedure development, coordination, approval and entry into force. Common cross-cutting requirements of labor protection and work safety.

Occupational safety standards system (OSSS) and its role in ensuring labor protection and work safety. The objects of standardization of the OSSS. The contents, classification and designation standards of the OSSS. The features of development, coordination and implementation of standards of the OSSS of the organizations using industry safety standards. The connection of the OSSS with other standards of the State standardization system. The procedure for the development and coordination of content and exposition of safety requirements in the standards

safety requirements as per the legislation of the Republic of Kazakhstan.

about the objectives, principles and directions of the state policy in the field of labor protection and work safety, on the main normative legal acts in the field of labor protection and work safety of the Republic of Kazakhstan.

317


and technical conditions. Types of content and scope, the rules of construction and safe operation of the facilities under the control of public oversight.

Typical and local instructions for labor protection and work safety. The content and order of presentation of security requirements, coordination, approval and implementation of the instructions.

Duties of workers and employees, the administration of organizations, labor groups, and the powers of the right of trade union committees to ensure labor protection and work safety.

The supervision and control of labor protection and work safety and the observance of labor legislation and its species. The government supervision and control and their rights. Responsibility for violation of labor legislation and safety requirements.

Topic 1.2. Management of labor protection

Labor protection and work safety as the objects of One describes the management of One describes the system of

318


control. The system “Management of labor protection and work safety”. The functions, tasks and methods of management of health and safety.

The control authorities for health and safety, their rights and duties. Regulation on the labor protection and work safety in the bodies of middle management. Regulation on the service of labor protection and work safety in organizations of primary (basic) level of management.

The perspective, prompt and comprehensive plan to improve the conditions of health and safety, sanitary measures. Funding for health and safety. Organization of training on occupational safety and health.

The goals, objectives, organization and briefings.

The documents for registration of training on occupational safety and health.

The features of the organization and training of persons performing the work regarding which have additional demands on labor protection and work safety.

labor protection in an organization. supervision and control, public control over observance of the legislation on labor protection and work safety. One explains the responsibilities of the employer and employees for violation of legislation on labor protection and work safety.

319


Test of knowledge performed by workers using safe working procedures.

Test of knowledge of the rules and standards of health and safety guidelines performed by technical officers.

Organizational maintenance of technical equipment, industrial processes, buildings and structures and duties of officials.

Organization of the corners, cabinets and mobile laboratories for labor protection and work safety.

Stimulating work on labor protection and work safety in the organizations.

.

Practical work No.1

The study of the development of the instructions for labor protection and work safety for a profession, and certain types of works.

One expounds the development of labor protection and work safety instructions of a profession and certain types of services.

One analyses the procedure of development of the instructions for labor protection and work safety.

Practical work No.2

320


The study of the order of reference documents on labor protection and work safety, organization of instruction on labor protection and work safety at the facility.

One expounds labor protection and work safety documentation procedure and organization of labor protection and work safety briefing at a facility.

One develops the order of carrying instructions on labor protection and work safety at the facility. One fills in the registration log of safety induction labor protection and work safety.

Section 2. . Improving the efficiency of the work on labor protection and work safety

Topic 2.1. Evaluating the effectiveness of safety management system

General information about the forms, goals, objectives, objects and methods of organizing and conducting of inspections and checks on the state of labor protection in the workplace.

Methods and techniques to identify hazardous and harmful factors, sources and incurred causes.

The procedure for organizing and conducting verification and certification of industrial equipment.

Monitoring the state of labor protection and work safety in the organization: purpose, the forms of control, the order of conduct of periodic

One characterizes the evaluation of efficiency of labor protection management system.

One explains the management system and occupational safety in the organization. One explains the procedure for organizing and conducting inspection and certification of industrial equipment and describes the purpose and types of the safety and labor protection in the organization.

321


inspection.

Topic 2.2. Recording and investigation of accidents

Determination of economic losses from injuries, illnesses, accidents and other accidents at work.

Definition and types of injuries, occupational diseases and accidents.

The regulation on the investigation and recording of accidents. The methods of studying the factors of industrial injuries.

Relative statistics assessment rates of the level of injury.

One expresses general judgments about the classification of hazardous and harmful factors and means of providing employees’ safety.

One expresses general judgments about the classification of hazardous and harmful factors, means of protecting workers. One explains the procedure for certification of workplaces on working conditions, compulsory insurance against industrial accidents and describes the types of injuries, occupational diseases and accidents at work.

Practical work No.3

Investigation of an accident at work. The development of measures to eliminate accident. The development of measures to prevent industrial accidents. Preparation of accounting and reporting documents.

One describes reasons of an occurrence of an accident and the development of accident elimination and prevention measures and fills documentation.

One sets up the cause of the accident, develops measures to eliminate and prevent accidents, and fills in documentation.

Section 3. Fire safety basics

322


Topic 3.1. Fire safety requirements

General information about the combustion and explosion, the causes and hazards of fire.

Terms and definitions adopted in the fire.

Influence of conditions and organization of technological processes, used materials and designs on fire safety. Properties and parameters determining the explosiveness and flammability of substances, materials and buildings. General fire safety requirements for industrial areas, buildings and facilities, technological processes. The classification of industries, areas and facilities for the explosion and fire hazard.

Fire safety system and its software. General information about the system in the prevention of heat. General information on the fire protection system.

Organizational and technical support of fire safety. Fire safety requirements in the OSSS, the Unified system for design documentation (USDD), the

Expounding the fire safety requirements for industrial spaces.

One unfolds the peculiarities of combustion, causes of fires in the workplace, the actions against the spread of fire, and characterizes the emergency routes and exits.

323


Unified system for technological documentation (USTD) and other regulatory documents. The issues of fire safety in the design, technology to the organizational and administrative documentation. Rules and instructions on fire safety.

The officials responsible for fire safety, and their duties and rights.

The organization of training work of rules of fire safety.

Participation of the personnel in fire safety. Fire-technical commission.

Prompt service and supervision of fire safety at enterprises engaged in fire safety authorities.

The features of fire safety and operations of fire prevention and fire protection in the industry.

The ways to improve fire safety and the role of leader in the organization of asset protection from fire.

Control work № 1

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Topic 3.2. Securing an object against fire

Fire safety of buildings and structures.

The tools and instruments for detection and automatic fire extinguishing.

The fire alarm and its installation.

The smoke protection system.

Extinguishing media and firefighting equipment, their types, the types of device, the scope and standards of equipment and accommodation on site.

The fire and water intake device.

Fire protection of software processes and production. Storage and use of flammable and combustible materials.

Fire safety of welding and other hot work.

Organization of fire fighting and fire tactics. The actions of workers at the detection of firing. Evacuation of people, equipment and materials. The equipment for extinguishing fires in different

One describes measures of providing fire safety on a facility.

One describes the system of fire safety of the industry. One sets out actions of workers in the detection of firing and describes the measures of extinguishing, primary fire extinguishing means, the installation and operation of fire alarm and communications.

325


environments and activities of public organizations on fire.

Practical work No.4

Analysis of the primary means of extinguishing fires.

The analysis of primary fire extinguishing equipment.

One collects and calculates the required number of primary fire extinguishing means and analyzes the device and operation of fire extinguishers and the rules for their application.


Analysis of the devices and operation of fire extinguishing installations.

The analysis of devices and of the operation of fire extinguishing installations.

One analyzes the device and operation of fire extinguishing installations.

Section 4. General hygiene requirements for the production facilities and jobs

Topic 4.1. General occupational hygiene, assessment of working conditions

Common hygiene as a basis for the development of labor law standards, sanitation-governmental rules and regulations of sanitary measures.

Influence of conditions, instruments and objects of labor, the organization of the labor process, the

One explains the physiological changes in the body during labor and ways to reduce operating fatigue.

One explains the physiological changes in the body during labor and ways to reduce operating fatigue.

326


degree of occupational safety and environmental conditions on the performance and health.

Basic physiology, psychology and ergonomics of work and work on the classification of severity of hazards and risks. Human-Computer Interaction.

Topic 4.2. Normalization of working conditions and sanitary maintenance of manufacture

Terms and industrial sanitation requirements.

The dependence of the choice of methods and means of sanitary-hygienic and sanitary-engineering production from climatic conditions, technology and organization of processes and production, materials, equipment, machinery, and other factors.

The organization of health surveillance carried out by the entity.

General and specific health rules for the organization of technological processes and hygienic requirements for production equipment, activities and means for their support. Sanitary classification of industries.

One explains the working conditions and industrial sanitary maintenance.

One is guided by hygiene and sanitation standards in the organization of processes and production, materials, equipment, machinery, and other factors.

327


General and specific requirements for the organization of occupational health workplace. The activities and means for their support. Sanitary protection zones of industrial organizations and other entities.

Topic 4.3. The microclimate and ventilation of the facilities

Meteorological conditions, climate and their components. Influence of meteorological conditions and the microclimate in the working.

Hygienic regulation parameters of meteorological conditions and climate.

The devices and methods of the study of climate and meteorological conditions.

Manufacturing acoustic and mechanical vibration and their influence on human health and the environment.

Protecting workers from the adverse effects of weather conditions and production harmful substances contained in the air. The devices for purification of air and other ways to normalize the

One explains the microclimate and ventilation of the facilities.

One explains the impact of climate on the job. One describes the means to ensure the normative parameters on climate.

328


working conditions.


Investigation of the meteorological conditions in the working place.

One draws up measures of addressing cases of non-compliance.

One defines the climate in the workplace and makes measures to address non-compliance.

Practical work No.5

Calculation of ventilation of production premises. The calculation of the amount of ventilation on production premises.

One calculates ventilation of production premises.

Topic 4.4. Protection against noise and vibration

The causes and the sources of noise. Classification of noise. Rationing noise and its sources.

Classification of vibrations, hygienic characteristics and rate of vibration.

The causes and the source of ultrasound and infrasound. Specifications and permissible levels of ultrasound and infrasound in the workplace

The methods measuring and controlling the level

One describes the characteristics of industrial noise and vibrations and provides explanation of their impact on human body.

One sets out the characteristics of the production of noise, vibration and explains their impact on the human body. One formulates the standards of human exposure.

329


and spectrum of noise, infrasound and ultrasound.

Safety and protection against noise and vibration. Organizational and technical measures directed to reduce noise and vibration.

Practical work No.6

The study of measures and means of protection against noise and vibration.

One determines the means and measures of protection against industrial noise and vibrations.

One analyzes the source of the noise and vibration. One defines the methods and means of protection against them.

Topic 4.5. Protection from exposure of industrial dust

Terms, causes and sources of the production of dust. Physical and chemical properties and classification of dust. Impact of industrial dust on the human body and the environment. Hygienic standardization of aerosol concentrations in the air of the working area. Methods and apparatus for determining dust.

One knows the principles of protection against exposure to industrial dust.

One defines harmful substances and their types. One explains the classification of dust. One describes measures for protection from exposure of hazardous substances.

Topic 4.6. Lighting of production facilities

Influence of light on workplace safety and productivity. Quantitative and qualitative

One describes the types of lighting on production facilities and its

One forms the basic concepts of light and describes the types of

330


indicators of industrial lighting. Types of industrial lighting depending on light sources. Types of artificial lighting production for other purposes. Rationing industrial lighting. The basic requirements of operation of lighting devices.

rationing. industrial lighting and rationing.

Practical work No.7

Determination of natural and artificial lighting of the workplace.

One describes natural and artificial lighting of a working place.

One specifies the workstation lighting, the rate of natural light and determines the parameters of the visual work for these jobs in this room.

Section 5. Legal and organizational issues of security and safety

Topic 5.1. Safety of technological equipment

Dangerous and harmful production factors, sources and their causes at the exploitation of a hand tool and process equipment.

General provisions and requirements of labor protection and work safety to the production equipment.

The organization of technical supervision for the

One determines the level of safety of a technological process and equipment and expounds general requirements applied to them.

One determines the safety of the process and equipment, sets out the general requirements for them. One describes the methods and means of safety equipment and communicates safe practices in the operation of technology and production equipment.

331


safety of technical equipment.

The officials responsible for the technical condition of production equipment, their duties and rights.

Safety requirements for the employees serving the industrial equipment.

Technical examination, registration and supervision of the state and the safe operation of production equipment, implemented by the state supervision.

Safe operation of hand and power tools. State standards and normals of industry tool. Rules of labor protection and work safety when using the tools.

Safety of manual and power tools, of the simplest hoisting machines and appliances. General safety requirements. Safety requirements for their structure. Special safety devices. Safety of ropes, cables, grips and pulling devices.

The workplace organization.

332


General safety requirements and their fulfillment at the organization and carrying out maintenance and repair of hand tools, industrial machines, mechanisms and vehicles in the workshops.

The security compressor units. General safety requirements. Specific requirements for the maintenance of compressor plants.

The ways of organizational and technical support and the role of the leader in improving safety of production equipment.

Topic 5.2. Process safety

The goals and objectives of the organization to ensure the safety of production processes.

General provisions and requirements for hanging safety of hazardous industrial sites provided by the system of standards of the OSSS, the USDD, the USTD and other statutory acts, and the dependence of these requirements on the type, method, form, regime and other terms of the process organization and used manufacturing equipment and materials.

One describes the organizing of safety of industrial processes.

One expands requirements for workplace equipment. One sets out the basic requirements for safety of used materials, parts, products, and waste production, storage and transportation. One describes the requirements for safety of production sites for the processes performed outside the production areas.

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The officials responsible for the safe operation of their duties and rights.

Safety requirements and security of the workers involved in the production process.

The establishment of technical supervision by the organization, the safety of production processes.

The questions of security and safety in the design, technological, organizational and administrative documentation. The organization of occupational labor protection and work safety of the workplace, the work area and site of the works. Hazardous areas.The requirements and measures to ensure labor protection and work safety in industrial processes.Safety requirements for technological processes, control and management of these processes.Safety requirements for industrial premises, equipment placement, organization of production, land and jobs. Organization of traffic routes, maneuvering.Safety requirements for used materials, parts, products, and waste production, storage and transportation. Safety requirements for the production site for the processes performed outside the production premises.

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Safety rules of assembly and dismantling, fitters-assembly works, metal processing, gas-electric and other special works in the test assemblies and machines. Special devices and accessories to ensure safe operation.

Topic 5.3. Protection from exposure of production radiation sources

Sanitation requirements and measures for the protection of sources of ionizing radiation from the workplace. The physical characteristics of thermal radiation. The biological activity of thermal radiation. The valuation effects of thermal radiation. The methods of protection against thermal radiation.

Biological effects of electromagnetic fields and used by the body's reaction. Valuation of electromagnetic fields, radio frequency and electromagnetic radiation sources.

Power frequency of electric fields, static electricity, and their effect on the human body. Permissible levels in the workplace.

Ultraviolet radiation and its sources. The biological effect on the organism and change of air medium under the influence of ultraviolet

One describes the peculiarities of providing an employee with protection against industrial radiation.

One describes the types of non-ionizing and ionizing radiation, the nature of their impact on humans. One communicates the valuation effects of thermal radiation, the methods and means of protecting workers from its negative impact. One is governed by the rules of safe operation of equipment with radiation.

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radiation.

Ionizing (radioactive) radiation and its effect on the environment and the human body.

Methods, devices for measuring and monitoring the parameters of regulated dangerous and harmful factors of generated magnetic and electric fields.

Topic 5.4. Basics of electrical safety

Safety of electrical consumers. Electric current and its effect on the human body. Risk of electrical networks and earth fault current. Characteristics and classification of premises on the degree of danger of electrical shock and the degree of protection against the attack. Types of work in electrical installations.

Electrical safety. The arrangements for ensuring the safe operation of electrical and electric facilities of the organization.

Energy service of a company. The officials responsible for the technical conditions of electric facilities and those responsible for the safe operation of the electrical installations, their duties

One expounds the basics of electrical safety.

One describes the types of electric current on the human body and the factors that determine the outcome of the defeat. One explains how to ensure electrical safety and protection.

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and rights.

Safety requirements and securities of workers serving the electrical consumers.

Safety requirements and safety during the inspection, maintenance and performance of works in the electrical installations. Safety work in the emergency situations. Technical methods, means and measures to ensure electrical safety, their characteristics and rational scope: inaccessibility and isolation of live parts, grounding, vanishing, safety shutdown and locking the alignment of potentials, electrical separation of networks and low voltage, protective equipment, lightning protection of buildings and structures, and etc.

The machinery, tools, and methods for measuring and monitoring electrical parameters.

Safe operation of mobile power, temporary electrical networks, electric hand tools and portable electric lamps.

Special requirements and features of ensuring the production of electrical work at the facilities and

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subsidiary companies of the industry.

Organization of service and operational control over the operation of electric consumers, conducted by the state oversight.

Practical work No.8

Providing first aid to the victim from exposure to electrical current.

One analyzes ways of providing first aid to a victim of exposure to electrical current.

One analyzes events to provide first aid and applies rules of rendering first aid to the victim from exposure to electrical current.

Topic 5.5. Hazardous and harmful industrial chemical factors

General information about occupational hazards, sources and reasons for their occurrence and impact of harmful factors on the human body. Classification of dangerous and harmful factors.

Chemical dangerous and harmful production factors. The classification of substances according to the degree of danger. The features of metal toxicity. The toxicity of certain substances and their compounds General hygiene requirements to the working zone. Harmful substances in the foundry industry and their effects on the human

One expounds hazardous and harmful industrial chemical factors.

One communicates dangerous and harmful production factors and explains safe working methods, optimal regimes of work and rest of employees.

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body. Carcinogens in foundries. The main sources of dust and gas emissions in the foundry industry.

Safety requirements and safety rules in the chemical laboratory.

Practical work No.9

Providing first aid to the victim from exposure to toxic substances.

One analyzes ways of providing first aid to victims of exposure to toxic substances.

One analyzes the measures to provide first aid and applies the rules of rendering first aid to the victim from exposure to toxic substances.

Control work № 2

Topic 5.6. Organization of fire protection in the industry

The features and measures to ensure fire safety.

The features and measures to ensure fire safety in the utility-ancillary organizations.

The fire regime in the organization. The fire prevention measures in repair shops, industrial machines, equipment and vehicles.

The features of human behavior during a fire, and

One describes the system of fire safety of the facilities industry.

One describes the system of fire safety of the facilities industry.

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the organization of the provision of first aid to the suffered.

Dealing with the consequences of fire.

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Guidelines

The following forms of organization of teaching are recommended in order to implement a training program on discipline “Safety and health management”: lectures, workshops, field trips, laboratory classes.



The educational program includes the study of basic measures for labor protection and work safety, possible safety hazards and fire safety.

The educational program is based on the knowledge gained from studying such disciplines as:

– Biology

– Chemistry

- Ecology and Sustainable DevelopmentThe knowledge gained from the study of the discipline used to learn the

following disciplines:

- Automation of foundry production

- Foundry equipment.


The control of this academic discipline provides for interim attestation the main forms of which are assessment paper, exams and tests.



- credit-1;

- exams- 1;




- basics of life safety, risk theories;

- rules of safety, industrial hygiene, fire safety and labor protection;

- tools and methods to improve the safety, environmental friendliness and sustainability of the technical means and technological processes;

- safety requirements at the working on the main and accessory equipment;

- operation of the support system of health support and safety of personnel of various organizations.


- measure and estimate the parameters of the working environment, the level of dust and gas pollution, noise and vibration, lighting jobs;

- carry out the control of electromagnetic, ionizing, thermal radiation and the level of negative impacts on their compliance to regulatory requirements;

- analyze the activities of the organization in order to identify risks in the field of labor protection and work safety, the health of staff;

- identify hazards of the working environment, assess the risk of their implementation.

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AUTOMATION OF FOUNDRY

The studied discipline is aimed at preparing students for the practical activities connected with the design of new equipment, modernization of the outdated one and the competent use of that being available for design offices and foundry shops.


Section, theme

Hours

all

including

laboratory work

practical

work

1 2 3 4

Introduction 1

Section 1. Equipment used for the preparation, storage and transportation of original molding materials

7 4

1.1. Equipment used for the storage and transportation of original molding materials

3 2

1.2. Equipment used for the reprocessing of burnt molding and core mixtures

4 2

Section 2. Equipment used for the mechanization of melting stock storages and melting compartments

12 2 2

2.1. Iron foundry shop equipment 6 2

2.2. Equipment used at the sites of a steel casting foundry shop producing shaped castings assigned for the preparation of melting stock

6 2

Section 3. Equipment used to provide foundry shops with compressed air

6 2

3.1. Compressors 2

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1 2 3 4

3.2. Ventilation facilities 4 2

Section 4. Kneading and mixing machinery 8 4

4.1. Mixers used for the preparation of molding and core mixtures

2

4.2. Equipment used for the preparation of molding and core mixtures

6 4

Section 5. Molding and core equipment 20 4 4

5.1. Equipment used for mixture compression by means of blanking

4 2

5.2. Equipment used for a mold in the process of shaking 4 2

5.3. Equipment used for impact compression of a casting mold 2

5.4. Equipment used for sand-blasting compression of a casting mold

4 2

5.5. Sand slingers (throwers) 4 2

5.6. Equipment used for vacuum and membranous molding 2

Section 6. Equipment used for cores and molds knockout, castings cleaning

18 8

6.1. Equipment used for foundry moulds knockout 4 2

6.2. Installations used for cores knockout 4 2

6.3. Installations used for castings cleaning 4 2

6.4. Installations used for castings fettling 3 2

Test No 1 1

6.5. Equipment used for castings painting 2

Total 72 16 14

Section 7. Equipment used for special casting methods 30 6

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1 2 3 4

7.1. Equipment used for chill mould casting 4

7.2. Equipment used for pressure die casting 4 2

7.3. Equipment used for low-pressure die casting and squeezing 4 2

7.4. Equipment used for die casting characterized by alloy crystallization

2

7.5. Equipment used for investment casting 2

7.6. Equipment used for centrifugal casting 4 2

7.7. Equipment used for shell casting 2

7.8. Equipment used for cavityless casting 4

7.9. Equipment used for continuous casting of ingots and shaped casting

4

Section 8. Lifting and hoisting machines used in foundry shops

6 2

8.1. Hoisting machines used in foundry shops 2

8.2. Transportation machines used in foundry shops 4 2

Section 9. Modern tendencies of casting equipment development

4

9.1. The elements of machines operation productivity theory 1

Test No. 2 1

9.2. Main methods of machines operation productivity increase 2

Course design 30

Total 70 8

Overall 142 16 22

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DISCIPLINE CONTENT

Theme content Results Assessment criteria

Introduction

Structure and content of a discipline “Automation of foundry”. Objective and tasks, course structure. Foundry engineering main development directions, technological processes and foundry engineering equipment interaction. Production machine block scheme. Machines’ operational characteristics and their interaction with a technology process. Machine’s operational characteristics and their interaction with design parameters of mechanisms. Foundry machines classification according to their structure, production-oriented application and automation degree. General requirements concerning foundry machines. The stages of new foundry machines development. Foundry machines design technique.

Students set forth general judgment concerning the content of a discipline “Automation of foundry”, the role of the module in the formation of professional skills, tasks faced by foundry men and engineering workers.

Students set forth general judgment concerning the content of a discipline “Automation of foundry”, the role of the module in the formation of professional skills, tasks faced by foundry men and engineering workers, the interaction with general educational and vocational study disciplines and special modules, main directions in the development of foundry production, interaction between technological processes and foundry production equipment, explain the block scheme of a production machine, technological characteristics of machines and their interaction with a technology process, explains machines operational characteristics and their interaction with design parameters of mechanisms, classify foundry machines according to their structure, production-oriented application and automation degree.

SECTION 1.


EQUIPMENT USED FOR THE PREPARATION, STORAGE AND TRANSPORTATION OF ORIGINAL MOLDING MATERIALS

Theme 1.1. Equipment used for the storage and transportation of original molding materials

Bins, silos and bunkers. Control and feeding gates. Dosing mechanisms. Equipment used for molding materials and mixtures transportation. Equipment used for the preparation of new molding materials. Driers for sand and clay: drying plates, pipe, horizontal and rotary as well as multiple-hearth driers, installations for the airflow sand drying. Installations for the drying of sand in a pseudo-boiling layer. Crushing and grinding equipment.

Students describe equipment used for storage and transportation of original molding materials.

Students explain the functional purpose of bins, silos and bunkers, describe the structure and operational principles of dosing mechanisms, equipment used for molding materials and mixtures transportation, equipment used for the preparation of new molding materials, equipment used for the airflow sand and clay drying, installations used for drying sand in a pseudo-boiling layer, give examples and describes the principles of crushing and grinding equipment operation.


Study of the structure and operational principle of a grinder, exploration of its operation modes.

Students describe the structure, application and the operation principles of a grinder, its operation modes.

Students analyze the structure, application and the operation principles of a grinder, its operation modes..

Theme 1.2. Equipment used for the reprocessing of burnt molding and core mixtures

Magnetic separators: drum, pulley and Students describe equipment used for Students explain functional purpose of 347


suspended separators. Rotary screens, jigging screens, vibrating screens. Burnt molding sand cooling. Evaporative cooling plants. Homogenizers. Burnt sand regeneration equipment.

reprocessing of burnt molding and core mixtures.

magnetic separators, explain the structure and operational principle of rotary, jigging and vibrating screens, methods and equipment used for burnt molding sand cooling, give examples and describe the principles of evaporative cooling plants operation, homogenizers and burnt regeneration equipment operation.


Study of the construction, magnetic separator operation analysis.

Students analyze the structure, application and the principle of a magnetic separator operation.

Students analyze the structure, application and the principle of a magnetic separator operation.

SECTION 2. EQUIPMENT USED FOR THE MECHANIZATION OF MELTING STOCK STORAGES AND MELTING COMPARTMENTS

Theme 2.1. Iron foundry shop equipment

Foundry shop melting stock storages equipment. Melting stock storages standard mechanization. Day bunkers and bins. Equipment used for the loading of stock into the cupola furnace: loading crane, inclined elevator, structure of a fixed and revolving inclined elevator. Сupola slag removal

Students characterize the iron foundry shop equipment.

Students describe and give examples of melting stock storages equipment in a foundry shop, provide standard block charts detailing melting stock storages mechanization, explain the operation principles of the equipment used for cupola melting stock removal, mechanization of the composition,

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mechanization. The mechanization of the composition, preparation and loading of melting stock charge in iron foundry shops practicing electric melting.

preparation and stock furnace charge in iron shops practicing electric melting.


Study of the structure, melting stock storages and melting compartments operation system.

Students analyze structure, application and the principle of melting stock storages and melting compartments equipment operation.

Students analyze structure, application and the principle of melting stock storages and melting compartments equipment operation.

Theme 2.2. Equipment used at the sites of a steel casting foundry shop producing shaped castings assigned for the preparation of melting stock

Manufacturing equipment of melting and casting compartments. Casting ladles. Ladles’ types. The mechanization of die casting performed at the foundry conveyor. Die casting automation, automated regulation of metal inflow, automated dosing, automated casting installations.

Students describe the equipment used at the sites of a steel casting foundry shop producing shaped castings assigned for the preparation of melting stock.

Students innumerate manufacturing equipment of melting and casting compartments, casting ladles and ladles’ types, describe the mechanization of die casting at the foundry conveyor, explain the principles of die casting automation, automated regulation of metal inflow, automated dosing and automated casting installations.


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Jaw-breaker and a roll crusher performance calculation.

Jaw-breaker and roll crusher performance calculation.

Students analyze the structure and calculate the performance of a jaw-breaker and a roll crusher.

SECTION 3. THE EQUIPMENT USED TO PROVIDE FOUNDRY SHOPS WITH COMPRESSED AIR

Theme 3.1. Compressors

Classification of air blowers and the scope of their application in foundry shops. Aerial system elements. Pipelines. Piston-type compressors.

Students expound classification of air blowers and the scope of their application in foundry shops.

Students classify air blowers and describe the scope of their application in foundry shops, explain the application of aerial system elements, pipelines and piston-type compressors.

Theme 3.2. Ventilation facilities

Centrifugal air blowers. Air blower and network integrated operation. Methods of ventilation facilities productivity regulation. Ventilation facility parallel and consecutive operation. General methods of ventilation facilities calculation within a foundry shop.

Students describe the application of centrifugal air blowers.

Students explain the application of centrifugal air blowers, describe the integrated operation of an air blower and a network, methods of ventilation facilities regulation, ventilation facilities parallel and consecutive operation, explain general methods of ventilation facilities calculation within a foundry shop.


Study of the system of air regeneration, its Students analyze the system of air Students analyze the operation principle of a

350


operation modes exploration. regeneration and research its operation modes.

foundry shop air regeneration system, give examples of the equipment used and justify its application.

SECTION 4. KNEADING AND MIXING MACHINERY

Theme 4.1. Mixers used for the preparation of molding and core mixtures

Mixers. Types of mixers characterized by discontinuous and continuous operation: chasers with vertical runners, centrifugal, twin mixers, mixers without runners, paddle mixers, rotary mixers and mixers of other types. Mixers operation automation.

Students describe the types of mixers of discontinuous and continuous operation and their operation basics.

Students provide explanation concerning mixers of discontinuous and continuous operation and their operation principle, explain the principles of mixer’s operation automation.

Theme 4.2. Equipment used for the preparation of molding and core mixtures

Detachers: cage mills, aeration towers. The equipment used for small-scale mechanization of molding mixtures preparation. Displaceable combination facilities. Mixture distribution along feed bunkers. Automated mixtures preparation systems.

Students describe equipment used for the preparation of molding and core mixtures.

Students explain the operation process of aeration towers, give examples of the equipment used for small-sale mechanization of molding mixtures preparation and explain the operation principle and the structure of automated mixture preparation systems.


Study of the structure and operation principles Students analyze the structure and Students analyze the structure and operation

351


of a screw mixer. operation principles of a screw mixer. principles of a screw mixer.


Study of the structure, operation principles and the management principle of mixtures preparation machines equipped with runners.

Student analyzes the structure, operation principle and the management of mixtures preparation machines equipped with runners.

Trainee analyzes the structure, operation principle and the management of mixtures preparation machines equipped with runners.

SECTION 5. MOLDING AND CORE EQUIPMENT

Theme 5.1. Equipment used for mixture compression by means of squeezing

Main operation parameters of squeeze molding machines. Molding mixture density distribution in the process of squeeze molding performance. Top and bottom squeeze molding. The reasons for mixture uneven density distribution in a casting box. Ways to level the degree of compression. Special methods to perform squeeze molding: squeeze molding performed under high specific pressure; squeeze molding performed using a rubber pad and hydro squeeze board; membrane filled with water; squeeze molding with preliminary pressure being performed;

Students expound the principles of the operation of equipment used for mixture compression by press moulding.

Students explains the operation principle of equipment used for the compression of a mixture by means of squeezing, describes main operation parameters of squeeze molding machines, the regulation of the degree of mixture compression in a molding box in the process of molding using squeeze molding machines, explain standard structure of squeeze molding machines and structural types of supporting frames (shoes) and columns of squeeze molding machines, compose design models, describe the methods of the specification of calculated static and

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layer by layer squeeze molding; vibratory molding; dynamic squeeze. The regulation of the degree of mixture compression in a casting box in the process of molding using squeeze molding machines. Typical structure of squeeze molding machines. Structural types of supporting frames (shoes) and columns of squeeze molding machines. Cross heads of squeeze molding machines (displaceable and immovable). Design models. The methods of specification of calculated static and dynamic loads while calculating strength of squeeze molding machines. Examples of squeeze moulding machines providing for modern structure.

dynamic loads while calculating strength of squeeze molding machines, give examples of squeeze molding machines providing for modern structure.


Study of the structure, operation principle and the exploration of the operation modes of squeeze molding machines.

Students analyze the structure and the operation principle of press moulding equipment, its operation modes.

Students analyze the structure and the operation principle of squeeze molding machines, their operation modes.

Theme 5.2. Equipment used for a mold in the process of shaking

Mold’s compression in the process of shaking. Shaking process scheme. Simplified model of

Students explain the operating principle of equipment used for

Students explain the principle of mold’s compression in the process of shaking,

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the process of molds’ compression in the process of shaking and its analysis. Requirements to the operation process of a jigger. The distribution of a molding mixture density in a mold while shaking. Additional mold’s compression in the process of shaking. The regulation of a degree of mixture compression in a molding box in the process of molding using jarring machines. Classification of jarring mechanisms according to the type of drive. Air-controlled jarring mechanisms: without and with a cutoff as well as with a cutoff and air expansion. Piston, spool-type and valve air distribution in air-controlled jarring mechanisms. Jarring mechanisms with buffering as well as with partial and full impact absorption.

compression of mold in the process of shaking.

compose the scheme of the process of shaking and analyzes it, sets forward the requirements to the operation process of a jarring mechanism, explain the distribution of molding mixture in the mold in the process of shaking, give examples of air-controlled jarring mechanisms and explain the principle of their operation.

Practical work No.2

Calculation of technical properties of air-controlled jarring molding machines without a cutoff and air expansion as well as with a cutoff and without air expansion.

Calculation of technical properties of air-controlled jarring molding machines without a cutoff and air expansion as well as with a cutoff and

Students analyze the structure of air-controlled jarring molding machines and calculate their performance.

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without air expansion.

Theme 5.3. Equipment used for the impact compression of a casting mold

Impact compression. Stress state of a mold (One-axle). The process of air filtration through the compressed mixture, inertial force effect. The effect of air pressure on the top of the mixture and the speed of the increase of pressure exerted on the mold’s density. The idea of a two-dimensional stressed state of a mold. Impact and squeeze compression. Impact molding machines. The process of gas outflow from a receiver into the mold’s flat surface. Operation process of high valves. The type of gas pressure in the process of burning and explosion. The structure of air-controlled molding machines of high pressure. The structure of machines used for explosive compacting. Air-controlled impact machines with low pressure recompacting. Valves. Distributors. Molds’ impact compression (high velocity compression). Mold’s stressed state (One-axle). The effect of speed, mass and configuration of a striker plate. Knocking gear

Students expound the mold’s stressed state (one-axle), the mechanism of a air filtration through the compressed mixture, inertial force effect, air pressure effect over the mixture and the speed of the increase of pressure exerted on the mold’s density.

Students explain the mold’s stressed state (one-axle), the mechanism of a air filtration through the compressed mixture, inertial force effect, air pressure effect over the mixture and the speed of the increase of pressure exerted on the mold’s density, disclose the idea of a two-dimensional stresses state of a mold, give examples of impact molding machines, explains the process of gas outflow from a receiver into the mold’s flat surface and operation process of high valves, describes the structure of air-controlled moulding machines of high pressure, the structure of machines used for explosive compacting, gives examples of air-controlled impact machines with low pressure recompacting, explains the mechanisms of molds’ impact compression, explains the operation process of a knocking gear, gives the properties of the structure of impact molding machines.

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operation process. The structure of a striker’s drive. The structure of impact moulding machines.

Theme 5.4. Equipment used for the sand-blasting compression of a foundry mold

The stages of the process of filling and impact compression. The influence of ventilation on the process. Sand-blowing and squeezing compression. Sand-blowing machines. The idea of a sand-blowing method employed for the manufacture of molds and cores. Process scheme. Main types of sand-blowing mechanisms. Main factors of the process. Physical model of a sand-blowing process, its mathematical formulation and analysis. Interaction of the parameters. Requirements to blow valves and exhaust valves. The calculation of the use of compressed air. Selection of the parameters of sand-blowing and sand-shooting machines. Design of sand-shooting heads billets and blasting plates for different types of molding and core mixtures. Types of blow and exhaust valves. Structural types of machines used for the manufacture of

Students describe the essence and operation mode of equipment used for sand blasting compression of a foundry mold.

Students explain the process of sand-blowing and squeezing compression, gives examples of sand-blowing machines, disclose the idea of a sand-blowing method employed for the manufacture of molds and cores, compose the scheme of a sand-blowing method of molds and cores manufacture, describe main types of sand-blowing mechanisms, main process factors, explain the physical model of a sand-blowing process, provide its mathematical formulation and performs the analysis, calculates the use of compressed air and selects the parameters of sand-blowing machines and shooters, explain the design of sand-shooting heads billets and blasting plates for different types of moulding and core mixtures, describe structural types of machines used for the manufacture of cores from sandy-clayey and oil mixtures, give

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cores from sandy-clayey and oil mixtures. Machines used for the manufacture of cores from the mixtures characterized by thermal and chemical hardening.

examples of machines used for the manufacture of cores from mixtures characterized by thermal and chemical hardening.


The study of the structure, operation principle of the equipment used for the manufacture of cores employing a sand-shooting method.

Students analyze the structure and the operation principle of the equipment used for the manufacture of cores employing a sand-shooting method.

Students analyze the structure and the operation principle of the equipment used for the manufacture of cores employing a sand-shooting method; calculate the parameters of sand-shooting heads.

Theme 5.5. Sand slingers

The idea of the process of sand-throwing machine molding. Main mechanisms of a sand-throwing machine and their functional application. The scheme of an impeller head of a sand-throwing machine, its operation and the stages of the operation process. Analysis of the operation process of a sand blowing machine impeller head according to the following stages: molding mixture entering the rotor, types of the systems feeding rotor with mixture, the interaction of the impeller’s and

Students describe the functional application of main mechanisms of sand-blowing machines and their functional application.

Students describe the process of sand-throwing machine molding, explain the functional application of main mechanisms of sand-blowing machines and their functional application, compose the scheme of the structure of a sand-blowing machine impeller head, describes its operation principle and the stages of the operation process, analyze the operation process of a sand-blowing machine impeller head, calculate the driving power of a sand-blowing impeller head, classify sand-

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mixture feeding systems parameters; encapsulation on the rotor blade, packet’s configuration, the compression of the mixture in the packet, friction of the packet against the guiding arc, mixture descent from the rotor blade, mixture compression in a molding box under the impact produced by mixture packets, the influence of a sand-blowing machine parameters on the quality of mixture compression. The calculation of sand blowing machine impeller head. Sand-blowing machines for the compression of self-hardening mixtures. The peculiarities of the structure and the operation process of wide-span sand-blowing impeller heads. The arrangement (classification) of sand-blowing machines. The peculiarities of sand-blowing machines strength calculations. Examples of sand-blowing machines modern structures.

blowing machines, explain the peculiarities of the strength calculation of sand-blowing machines parts, give examples of sand-blowing machines modern configurations.


Calculation of geometrical parameters and technical properties of sand-blowing machines impeller head.

Calculation of geometrical parameters and technical properties of sand-blowing machines impeller head.

Students analyze the configuration of a sand-throwing machine impeller head and calculate its geometrical parameters and technical

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properties.

Theme 5.6. Equipment used for vacuum and membranous molding

Stressed state and strength of molds in the process of vacuum compaction before and in the process of casting. Gas filtration. Machines used for vacuum and membrane molding. Membrane application installation. The calculation of pump’s capacity. The mechanisms of assembly and transportation of molds for further casting. The comparison of the methods of compression, the scope of application of each method.

Students describe the purpose and operation principles of .equipment used for vacuum and membranous molding.

Students explain the stressed state and strength of molds in the process of vacuum compaction before and in the process of casting, gas filtration principle, give examples of machines used for vacuum and membrane molding, explain the operation principle of the facility used for membrane application, calculates the productivity of a pump, describe the mechanisms of assembly and transportation of molds for further casting, compare the methods of compression, explain the scope of the application of each method.

SECTION 6.EQUIPMENT USED FOR CORES AND MOLDS KNOCKOUT, CASTINGS CLEANING

Theme 6.1. Equipment used for foundry molds knockout

The methods of clump and casting removal from a molding box: vibratory, impact and by means of squeezing. Stressed state of a clump while experiencing impact or while squeezing. Process optimal parameters. The methods of

Students describe the operation of equipment used for foundry molds knockout.

Students describe the methods of clump and casting removal from a molding box, the separation of mixture and casting, explains the operation process of a cammed knockout grates and frames, select operation

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mixture and casting separation. Process parameters. Pneumatic (vibratory) knock-out. Knock-out grades (grids) and frames. Grades and frames drive mechanism: pneumatic, camshaft and inertia. Operation processes of cammed (eccentric) knock-out grates and frames. Operation parameters identification. The types of the structures of bearing, bumper and joint boxes inertial grates and frames mechanisms The structure of inertia grates and frames. The operation process of impact knockout installations. Piercing knockout installations. The identification of technological parameters. The identification of rated force. Calculation of the diameter of a knockout mechanism cylinder. Airvoid knockout installations. Appliances used for the separation of castings and mixture: grates and drums. Automated installations used for the knockout of molds at the foundry (casting) conveyor. Installations used for the knockout of molds with crossbars in bottom molding boxes. Installations used for the knockout of molds without crossbars in bottom molding

parameters, gives examples of the options of the structures of mechanisms of inertia grate and frame, describe the operation process of impact knockout installations, identifies technological parameters and rated force, explain the operation principles of vacuum knockout installations, gives examples of automated installations used for the knockout of molds at the casting conveyor, explains the structure of knockout installations mechanisms, practices and methods of safety operation during maintenance of the equipment for casting molds knockout.

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boxes. The structure of knockout installations mechanisms of push bars, compressor bars, tables used for the change of direction movement, carriages used for molding boxes transportation.

Practices and methods of safety operation during maintenance of the equipment for casting molds knockout.


Calculation of technical properties of eccentric, inertia, inertia and impact knockout grate.

Calculation of technical properties of eccentric, inertia, inertia and impact knockout grate.

Students analyze the structure of knockout grates and calculate main technical properties.

Theme 6.2. Installations used for cores knockout

Methods of core destruction in a casting, vibratory, elecrohydraulic, hydraulic, sand and hydraulic. Mechanisms of core destruction, parameters of the destruction processes. Vibration machines. Hydraulic and sand and hydraulic installations. Sump modes calculation. The structure of hydraulic and sand and hydraulic installations and their

Students describe the structure of hydraulic and sand and hydraulic installations and their mechanisms, practices and methods of safety operation during maintenance of the equipment for casting molds knockout.

Students explain the methods of cores destruction in a casting, describe the nechanisms of cores destruction, destruction processes parameters, give examples of vibration machines, explain the structure of hydraulic and sand and hydraulic installations and their mechanisms, practices and methods of safety operation during maintenance of the

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mechanisms, hydraulic monitor, its drive, hydraulic pumps, carts (carriages), jiggers. Electrohydraulic installations used for cores knockout. Shotblaster knockout installations. Practices and methods of safety operation during maintenance of the equipment for casting molds knockout.

equipment for casting molds knockout.


Calculation of main technical properties of the installationa used for hydraulic knockout of cores.

Calculation of main technical properties of the installation used for hydraulic knockout of cores.

Students analyze the structure of installations used for hydraulic knockout of cores and calculate main technical properties.

Theme 6.3. Installations for castings cleaning

Metal penetration destruction methods. Methods of metal penetration destruction in the process of shotblaster cleaning. Process optimal parameters. Metal penetration chemical and electrochemical destruction. Installations classification. Tumbling barrels. Calculation of the number of the revolutions of tumbling barrels. Calculation of driving power. The structure of barrels of discontinuous and continuous operation.

Students describe the methods of the methods and ways of metal penetration destruction in the process of shot blaster cleaning and expound the operation principles of casting cleaning installations.

Students provide the methods and ways of metal penetration destruction and describes the mechanisms of metal penetration destruction in the process od shot blaster cleaning, select the optimal parameters of the process, classifies the installations, explain the calculation of the number of revolutions of tumbling barrels, driving power, give examples of the structure of barrels of discontinuous and continuous operation,

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Equipment used for casting shotblaster cleaning. Selection of the parameters of rags stream according to the practical data. Shotblaster. Classification of shotblasters according to the method of shot feeding to the rotating blades. Operation processes of impeller and non-impeller device. The ways to increase the productivity of shot blasters. The structure of modern shot blasters. Shot blasting installations: rotoblast barrels of discontinuous and continuous operation, shotblaster tables, go and no-go shot blast cameras. The structure of shot blasting installations and mechanisms. Shot blasting installations: operation principle, selection of parameters according to practical data, installation construction and its mechanisms. Practices and methods of safety operation during maintenance of the equipment for casting molds knockout.

equipment used for casting shotblaster cleaning, select the parameters of rags stream according to the practical data, classify shotblasters according to the method of shot feeding to the rotating blades, describes the operation process of impeller and non-impeller device, explain the structure of modern shot blasters, practices and methods of safety operation during maintenance of the equipment for casting molds knockout.


Calculation of main technical properties of tumbling drums of continuous and a

Calculation of main technical properties of tumbling drums of

Trainee analyzes the structure of a tumbling drum of continuous operation and a shotblast,

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shotblaster. continuous and a shotblaster equipment.

calculates its main technical properties.

Theme 6.4. Installations used for castings fettling

Dressing performance using sand discs. Selection of a sand disc and the parameters of its operation. Types of multiwork machines: stationary, pendulum and portable. Specialized machine tools used for the fettling of technologically similar castings. The structure of feeding devices. Practices and methods of safety operation during maintenance of the equipment for casting molds knockout. Handling devices and robots used for the cleaning of castings.

Students expound the technique of castings’ fettling using sand discs, the principle of sand disc selection and its operation parameters.

Students describe the purpose and operation principle of casting fettling equipment.

Students explain the technique of castings’ fettling using sand discs, the principle of sand disc selection and its operation parameters, give examples of multiwork and specialized tools used for the fettling of castings, describe the structure of feeding devices, practices and methods of safety operation during maintenance of the equipment for casting molds knockout. Gives the examples of handling devices and robots used for the cleaning of castings.

Test No.1


Selection of sand disc used for the cleaning of castings.

Selection of sand disc used for the cleaning of castings.

Students analyze the operation parameters and selects a sand disc used for the cleaning of castings.

Theme 6.5. Equipment used for castings painting

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Classification and marking of lacquer coating. The equipment used for the painting of castings – paint dipping, paint spraying and paint laydown in the electric field. Appliance used for castings drying. Meta and non-metal inorganic coatings. Properties and the scope of application. Practices and methods of safety operation during maintenance of the equipment for casting molds knockout.

Students expound the purpose and operation principle of casting painting equipment.

Students classify lacquer coatings, describe the equipment used for castings painting, appliance used for castings drying, practices and methods of safety operation during maintenance of the equipment for casting molds knockout.

SECTION 7. EQUIPMENT USED FOR SPECIAL FOUNDRY METHODS

Theme 7.1. Equipment used for chill mold casting

Classification of chill moulding machines according to basic properties. Mechanism of chill mould blockage. The system of chill mould heating and cooling. Appliances and mechanisms used for the demolition of mechanical cores. Chill moulding machines with hand drive. Machines with hydraulic and pneumatic drive. Casting machines used for chill mould patterns 5912, 3915, 5924. Multitask machines of models 5944, 5966. Modularized and special chill moulding

Students describe the system of chill mould heating and cooling, appliances and mechanisms used for the demolition of mechanical cores.

Students classify chill moulding machines according to the basic properties, explain the operation principle and chill mould blockage mechanism, describe the system of chill mould heating and cooling, devices and mechanisms used for the demolition of mechanical cores, disclose the principle of the operation of automated machines used for the manufacture of castings into surfaced chill mould.

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machines of models 5946, 59С1, 59С19. Automated machines used for the manufacture of surfaced chill mold castings.

Theme 7.2. Equipment used for pressure die casting

Main schemes of die casting. Design schemes of machine’s pressing mechanisms. The sequence of the calculation of parameters of pressing and blocking mechanisms. Appliances used for lubrication of press- molds. Monitoring of technological modes of machines operation. Monitoring of the transfer and speed of a press plunger. Monitoring of squeezing. Monitoring of the effort of press- mold blockage. Automated systems of the management of die casting processes. Automated complexes of die casting.

Students describe the purpose and operation principle of pressure die casting equipment.

Students compose basic schemes of die casting and design schemes of machine’s pressing mechanisms, explains the calculation of the parameters of pressing and blocking mechanisms, the order and principle of the operation of a device used for press-mold lubrication, describe the monitoring of technological modes of machine’s operation, transfer and speed of press plunger, pressing concept, efforts of press-mold blockage, give examples of automated systems of die casting process administration and automated complexes of die casting.

Practical work No.8

Calculation of the parameters of pressing and blocking mechanisms.

Calculation of the parameters of pressing and blocking mechanisms.

Trainee analyses the structure of pressing and blocking mechanisms and calculates the parameters.

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Theme 7.3. Equipment used for low-pressure die casting and squeezing

The scheme of the process of die casting and counterpressure. The sequence of the calculation of the operation pressure value. The structure of a metal feed pipe and the calculation of its inside diameter. Types of installations and technological schemes of die casting.

Students compose the scheme of die casting process and with counterpressure and describe the purpose and operating principle of low-pressure die casting and press-moulding equipment.

Students compose the scheme of die casting process and with counterpressure, explains the calculation of the value of operation pressure, the structure of a metal feed pipe and the calculation of its inside diameter, give examples of different types of installations and technological schemes of die casting.

Practical work No.9

The calculation of inside diameter of a metal feed pipe.

The calculation of inside diameter of a metal feed pipe.

Students analyze the structure of a metal feed pipe and perform the calculation of its inside diameter.

Theme 7.4. Equipment used for die casting characterized by alloy crystallization

The basic scheme of the process of die casting characterized by alloy crystallization under pressure and its variations. The structure of a press-mold with movable die, stationary die and a composite die. Pressure equipment. Press selection. Pneumatic presses and installations. Installations used for regulated pressure casting.

Students describe the equipment used for die casting characterized by alloy crystallization.

Students compose basic scheme of the process of die casting characterized by alloy crystallization under pressure, describes the structure of a press-mold with movable die, stationary die and a composite die, innumerate pressure equipment, selects presses.

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Theme 7.5. Equipment used for investment casting

The scheme of a basic process of investment casting. Equipment used for the manufacture of investment models. The manufacture of molding composites and their further preparation (the installation of models 651 and 652А, automated devices, model 61701, 653, 61201). Extrusion-machine of the model 659А. The equipment used for the manufacture of models from basic composites (МОН-10К, МПВС-2). The installation used for vacuum and ammoniac drying of the model (pattern) УВС-4 for ceramic coatings. Installations used for the separation of castings and downgates of the model УВИГ-240.

Students describe the purpose and operating principle of investment casting equipment.

Students compose the scheme of a basic process of investment casting, innumerate the equipment used for the manufacture of investment models, describe the process of the manufacture of molding mixtures (composites) and their preparation, principle of the operation of the installation used for vacuum and ammoniac drying of ceramic coatings.

Theme 7.6. Equipment used for centrifugal casting

The essence of centrifugal casting. The structure of centrifugal machines. The sequence of the calculation of the speed of an ingot mould revolving. Drive. Casting device. Centrifugal machines with vertical and horizontal axes of rotation.

Students describe the purpose and operating principle of centrifugal casting equipment.

Students disclose the essence of the method of centrifugal casting, describe the structure of centrifugal machines and explain the calculation of the speed of axes rotation..

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Practical work No.10

Casting device rotation speed calculation. Casting device rotation speed calculation

Students analyse the structure of centrifugal machines and perform the calculation of casting device rotation speed.

Theme 7.7. Equipment used for shell casting

The essence of the method of shell casting. Equipment used for the preparation of sandy and resinous mixtures, manufacture of shell molds and the knockout of castings from them. Automated complexes used for shell casting.

Students describe the essence and operating principle of centrifugal casting equipment.

Students disclose the essence of the technique of shell casting, describe the equipment used for the preparation of sandy and resinous mixtures, manufacture of shell molds and the knockout of castings from them, innumerate the automated complexes used for shell casting.

Theme 7.8. Equipment used for cavityless casting

The essence of the technique of cavityless casting. Equipment used for the squeeze of models from cellular polystyrene, automated devices used for the manufacture of models from polystyrene. Equipment used for painting, drying and molding. Devices used for the feed-heads separation.

Students characterize equipment used for cavityless casting.

Students explain the essence of the process of cavityless casting, describe the equipment and automated devices used for the squeeze of models from polystyrene, equipment used for the painting, drying and molding as well as devices used for feed-heads separation.

Theme 7.9. Equipment used for continuous casting of ingots and shaped castings369


The essence of the process. Crystallization equipment and pallets. Electro-magnetic crystallization equipment used for the casting of extrusion billets and flat-shaped ingots. The installations used for continuous electro-magnetic crystallization casting devices, the equipment used for semicontinuous shaped casting.

Students describe the operating principle of equipment used for continuous casting of ingots and shaped castings.

Students explain the essence of the process of continuous casting of ingots and shaped castings, gives examples of the equipment and describe the functional application of its basic mechanisms, innumerate the equipment used for semicontinuous shaped casting.

SECTION 8. LIFTING AND HOISTING MACHINES USED IN FOUNDRY SHOPS

Theme 8.1. Hoisting machines used in foundry shops

Overhead travelling electric cranes, frame-cranes and electric hoists. Specific indicators of hoisting and transportation equipment. Modes and conditions of the operation of hoisting and transportation equipment. Classification and structure of brakes of hoisting and transportation equipment. Hoisting machines, types of hoisting machines and their structure.

Students describe hoisting machines used in foundry shops.

Students describe specific indicators of hoisting and transportation equipment, modes and conditions of its operation, explain the classification and the structure of hoisting and transportation equipment brakes, innumerate the types of hoisting machines and their structure.

Theme 8.2. Transportation machines used in foundry shops

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Casting and trailer conveyors. Walking conveyors. Rocker and dual-duty conveyors. Pneumo- and vibrating transport. Conveyor tables. Drag devices: band belts, slat conveyor, scraper conveyor, and swinging and screw conveyor. The scope of the application of transportation devices, operation peculiarities. The elements of constructions, calculation of the productivity and towing force. The scheme of addressing and delivery of materials to customers. Applications used for the collection of waste left after foundry shop operation.

Students describe the operating principle and purpose of transportation machines used in foundry shops.

Students set forth the scope of the application of transportation devices, their operation peculiarities, explain the elements of constructions, calculation of the productivity and towing force, describe the scheme of addressing and delivery of materials to customers.

Practical work No.11

Calculation of towing force of conveyors of different types.

Calculation of towing force of conveyors of different types.

Students analyze the structure of conveyors of different types and constructions and calculate their towing force.

SECTION 9. MODERN TENDENCIES OF FOUNDRY EQUIPMENT DEVELOPMENT

Theme 9.1 Machines productivity theory elements

The theory of labour productivity. New machinery efficiency. Main directions in the increase of labour productivity in the process

Students expound machines productivity theory elements.

Students explain main provisions of the theory of labour productivity, describe principal directions in the increase of labour

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of casting equipment manufacture. Losses of efficiency, their productivity and analysis.

productivity in the process of casting equipment manufacture.

Test No. 2

Theme 9.2. Main methods of machines’ operation productivity increase

Main methods of the increase in machines productivity: processes intensification, synchronization and apart performance of technological operations in the area. Technologic basics of the methods and their implementation in the process of structure and machines’ components selection.

Students expound main methods of machines’ operation productivity increase.

Students describe main methods of the increase in machines productivity, disclose technological basics of the methods and their implementation in the process of structure and machines’ components selection.

Course project design

Сourse design is aimed at the design of a production machine or installation specific for the casting production, apart element or mechanism of an automatic foundry line. The theme of the course project complies with the real objectives of automation and mechanization in foundry manufacture. Project should reflect the issues of the development of mechanization and automation of

Course project. While designing the course project students are to perform the design of a production machine or installation specific for the casting production (manufacture), apart element or mechanism of an automatic foundry line, to reflect there the issues of the development of mechanization and automation of technological processes as well as to introduce new advanced processes and high-

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technological processes, the introduction of new advanced processes and high-performance equipment. The amount of graphics in the course project makes up 3-4 pages.

performance equipment.

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GuidelinesTo implement the training program on the Foundry equipment we

recommend the following forms of training: lectures, seminars, field trips, as well as laboratory and practical classes.

Given the nature and complexity of the content of the educational material the following training methods are recommended: lectures, conversations, discussions, solution of situational problems, analysis of work situations, role-playing and simulation games, brainstorming, presentation of the material, work in small groups and others.

These forms of cognitive activities are advisory by their nature. The number of hours to study the sections can be changed while maintaining the minimum content.

This training program aims to:- teach students a system analysis of the structure, purpose and principles of

foundry equipment operation;- to study the physical phenomena all foundry equipment is based upon.The Foundry equipment academic discipline is based on the knowledge

gained from studying such disciplines as Chemistry, Mathematics, Physics, Drawing, Basics of technical mechanics.

The knowledge gained from the module is used when studying the following disciplines:

- Foundry Industry Automation;

- Foundry Theory and Technology;

- Rigging Design.

Studying the academic discipline it is necessary to integrate it with the academic disciplines belonging to general professional and special cycle.

The control of this academic discipline provides for interim attestation the main forms of which are assessment paper, credit, exam and tests.



-course project - 1

- credit-1;

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- exams- 1;



Having studied the discipline a student must know:

- how various types of machines are organized them being combined into technological groups and ensuring implementation of foundry major technological cycles;

- calculation methods of the main casting machines assembly units;

- design principles of mechanized and automated systems on the basis of casting machines, programmable manipulators and robots;

- rules of casting machine maintenance and operation;

- modes and conditions of operation of materials handling equipment;

- methods of diagnosing the state of the equipment as well as systems based on casting machines, programmable manipulators and robots;

be able to:

- carry out a technical and economic analysis of various options to equip foundries with most progressive casting machines;

- to solve engineering problems related to the development and improvement of new foundry equipment;

- to carry out the layout of equipment for different process stages in accordance with the required casting technology;

- to analyze the structure of conveyors and calculate their traction efforts;

- to solve the problems associated with the maintenance and repair of foundry equipment as well as its modernization.

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DESIGN AND TECHNOLOGICAL BASIS FOR THE PRODUCTION OF MOULDS FOR MACHINE MOLDING

The purpose of the discipline is to develop the students' knowledge in the field of machine core molding in the production of castings.


Topic

Number of hours

allincluding for

practical works

Introduction 1

1. Requirements for the cores and their operating conditions 6 4

2. Formulation of mixtures for machine core molding in the production of castings

4 2

3. Design and operation of core machines 4 2

4. Design of core boxes 2

Control work 1

5. The control methods of technological properties of core mixtures

4 2

Total 22 10

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Introduction

The structure and content of the discipline “Design and technological basis for the production of moulds for machine molding”. The purpose and objectives of the course. The role of academic discipline in forming professional knowledge, skills of students. The prospects for the development of machine core production.

One expresses an overall judgment on the content of the training course “Design and technological basis for the production of moulds for machine molding "on the objectives, the role of academic discipline in formation of professional knowledge and skills.

One expresses an overall judgment on the content of the training course “Design and technological basis for the production of moulds for machine molding”, on the objectives, the role of academic discipline in formation of professional knowledge and skills. One names the prospects of development of machine cores production.

Topic 1. Requirements for the cores and their operating conditions

The technology of core manufacturing. Curing and core drying. The rules for placing of gas outlets. The procedure for the production of cores on machines and automatic machines of various types, including program-controlled ones. The rules of installation of carcasses, trims, mounting cores and laying them to dry. The ways to assemble the cores of all types of difficulty. The quality requirements imposed on the finished

One expounds the requirements for cores and their operating conditions.

One describes the technology of core manufacturing, curing and core drying, rules of placing of gas outlets. One sets out the procedure for the core production on machines and machines of various types, including the ones with program management, quality requirements imposed on the finished cores.

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cores.


The core making with core boxes on the machines. One manufactures cores with machines per core boxes.

One makes the cores using core boxes on the machines.


Performance of quality control for the cores. One researches measures of quality control of manufactured cores.

One controls the quality of the finished cores.

Topic 2. Formulation of mixtures for machine core molding in the production of castings

Composition of core sand mixtures and other auxiliary materials used in the manufacture of cores and requirements for them. The methods for preparing core mixtures. Influence of binders on the physical and mechanical properties of the core sand and the quality of the cores.

One expounds compositions of core mixtures and other auxiliary materials used in the manufacture of cores and requirements for them.

One describes compositions of core mixtures and other auxiliary materials used in the manufacture of cores and requirements for them. One refers to the methods for preparing core mixtures. One explains the effect of binders on the physical and mechanical properties of the core sand and the quality of the cores.


The study of the compositions of core sand mixtures.

One recreates a core mixture composition.

One analyzes the compositions of core sand mixtures.

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Topic 3. Design and operation of core machines

The arrangement device and operation of the maintained core-making machines and automation devices. .The rules of control of core-making machines. Design and operation of lifting devices and mechanisms. Appointment and conditions of use of tools and equipment. Methods and practices of secure operation during maintenance of core machines and automation devices.

One explains the design and operating principles of maintained core machines and automation devices, the rules of control of them.

One explains the arrangement device and operation of the maintained core-making machines and automation devices, the rules of control of them. One explains the appointment and conditions of use of tools and equipment, methods and practices of secure operation during maintenance of core machines and automation devices.


Mastering the techniques of service and commissioning of core-making machines.

One masters the techniques of service and commissioning of core-making machines.

One performs maintenance and produces adjustment of core-making machines.

Topic 4. Design of core boxes

The construction, the basic principles of design and operation of core boxes, jigs and tooling. The procedure for preparation of core boxes (inspection, cleaning, applying coating separation).

One expounds the design of core boxes.

One describes the construction, the basic principles of design and operation of core boxes, jigs and tooling. One names the procedure for preparing core boxes.

Control work

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Topic 5. The control methods of technological properties of core mixtures

Quality control of core sand mixtures. The methods of determining their physical and mechanical properties and quality.

One describes the methods of determining their physical and mechanical properties and quality and quality of core sand mixtures.

One describes the methods of determining their physical and mechanical properties and quality and quality of core sand mixtures.

Practical work No.5

The check of the quality of core sand mixtures. One checks the quality of core sand mixtures.

One performs the check of the quality of core sand mixtures.

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Guidelines

The following forms of organization of teaching are recommended in order to implement a training program on discipline “Design and technological basis for the production of moulds for machine molding”: lectures, workshops, field trips, laboratory classes.



This training program provides:- teaching students for analysis of the quality of core mixtures;- study of technology of core making and the device and operation of the

maintained machines.The discipline “Construction and technological bases of machine core

molding” is based on the knowledge gained in the study of educational discipline “Chemistry”, “Physics”, “Drawing”.

The knowledge gained from the study of the discipline is used in the study of the following discipline:

- Theory and technology foundry production



The control of this academic discipline provides for interim attestation the main forms of which are assessment paper, credit and tests.



- credit-1;


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- requirements for the cores and their operating conditions;

- typical recipes of mixtures for machine core molding in the production of castings from iron-based alloys and non-ferrous metals;

- design and operation of the core machines;

- methods of calculation of the linear dimensions of core boxes;

- methods of control of technological properties of core mixtures;


– maintain and make adjustment to core machines;

- produce cores for core boxes in machines;

- control the quality of the cores;

- collect and glue cores.

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THE SYSTEMS OF COMPUTER-AIDED DESIGN AND SIMULATION OF FOUNDRY PROCESSES

The purpose of the study of the discipline is to develop the students' knowledge in the field of mathematical modeling of foundry processes, software and innovative manufacturing processes of foundry tooling.


Topic

Number of hours

all

including hours for laboratory

works

Introduction 1

1. Basic concepts of CAD system. General provisions 1

2. Use of CAD system in foundry production. 2

3. Construction of molded pieces 2

4. Design automation of casting technology 2

5. Methods of numerical solution of differential equations for modeling of casting processes

1

6. Computer modeling system of casting processes 9 8

7. Simulation of hydrodynamic and thermal processes in the system “Polygon”

8 6

8. Models of porosity formation in modeling system “Polygon” 6 4

9. The deformation model in the system “Polygon” 3 2

10. Thermodynamics and kinetics of cast iron crystallization: computer analysis

1

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11. Professional system of computer modeling of casting processes “ProCAST”

16 14

12. Innovative production processes of manufacture of foundry tooling

1

Control work 1

13. Modern technological processes for production of foundry tooling

2

Total 56 34

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Introduction

The structure and content of the module “The systems of computer-aided design and simulation of foundry processes”. The purpose and objectives of the course. The role of the module in the formation of professional knowledge, skills of students. Designing with computers in the production cycle. Place of graphics in computer-aided design. Automated systems.

One expresses an overall judgment on the content of the module “The systems of computer-aided design and simulation of foundry processes”, on goals, objectives and role of the module in the formation of professional knowledge and skills for the design using a computer in a production cycle.

One expresses an overall judgment on the content of the module “The systems of computer-aided design and simulation of foundry processes”, on goals, objectives and role of the module in the formation of professional knowledge and skills for the design using a computer in a production cycle. One determines place of graphics in computer-aided design and automated systems.

Topic 1. Basic concepts of CAD system. General provisions

Basics of computer-aided design system (CAD system). General provisions. The structure of the design process. Formation of the production database.

A student expresses a general judgment on CAD system.

A student expresses a general judgment on CAD system. One describes design process and the order of formation of database.

Topic 2. Use of CAD system in foundry production

Conditions and problems of development of CAD processes of foundry production. Challenge of using

One describes the state and tasks of CAD processes of

One describes the state and tasks of CAD processes of foundry production. One poses as a

385


computers in the foundry industry. foundry production. challenge the use of computers in the foundry industry.

Topic 3. Construction of molded pieces

Requirements for configuration of details. Criteria of reliability of cast parts. Selecting the rational design of the molded piece. The types of analysis performed using software packages ANSYS, NASTRAN, COSMOS.

One describes the construction of molded pieces.

One sets out the requirements for configuration of details. One explains the reliability criteria of cast parts and describes the range of rational design of the molded pieces, the types of analysis performed using software packages ANSYS, NASTRAN, COSMOS.

Topic 4. Design automation of casting technology

Development and use of information retrieval system. Coding casts using optimal casting technology.

One describes the order of development and use of information retrieval while automating design of casting technology.

One can describe the order of development and use of information retrieval system and explains coding process of casts using optimal casting technology.

Topic 5. Methods of numerical solution of differential equations for modeling of casting processes

The types of methods for the numerical solution of differential equations for modeling of casting processes. The methods of boundary elements, finite volume, finite differences and finite elements.

One expounds the methods of numerical solution of differential equations for modeling of casting

One name types of methods for the numerical solution of differential equations for modeling of casting processes and describes methods of boundary elements, finite volume, finite

386


processes. differences and finite elements.

Topic 6. Computer modeling system of casting processes

Computer modeling systems “ProCAST”, “Polygon”, “MagmaSoft”, “AFSSolidificationSystem”, “LWMFlow”, “Simtec”, “I-DEAS” and etc. The functionality of the modeling systems. Sequence of computer modeling of casting processes. Databases of systems computer simulation.

One describes computer modeling systems of casting processes.

One can describe computer modeling systems “ProCAST”, “Polygon”, “MagmaSoft”, “AFSSolidificationSystem”, “LWMFlow”, “Simtec”, “I-DEAS” and etc. One explains functionality of the modeling systems and sequence of computer modeling of casting processes and their databases.


Design of foundry mold. One designs a foundry mold.

One can design a foundry mold.


Creating a project of a detail-casting. Connecting values of elements sizes.

One creates a project of a detail-casting. One connects values of elements sizes.

One creates a project of a detail-casting. One connects values of elements sizes.


Creation of the base of foundry mold and the intermediate assembly. Centering the projected part in the base of foundry mold.

One creates the base of foundry mold and the intermediate assembly and

One creates the base of foundry mold and the intermediate assembly. He performs centering the

387


performs centering the projected part in the base of foundry mold.

projected part in the base of foundry mold.


Creating three-dimensional solid models in CAD system.

One creates three-dimensional solid models in CAD system.

One creates three-dimensional solid models in CAD system.

Topic 7. Simulation of hydrodynamic and thermal processes in the system “Polygon”

System unit “Polygon”. The principles of the solution of the thermal problem, hydrodynamics, filling a form. Calculation of the deformation processes.

One analyzes the principles of the solution of the thermal problem, hydrodynamics, filling a form.

One names system units “Polygon”. One sets out the principles of the solution of the thermal problem, hydrodynamics, filling a form. One calculates deformation processes.


Working with preprocessing and settlement system units “Polygon”. Processing and analysis of simulation results.

Working with preprocessing and settlement system units “Polygon”. Processing and analyzing simulation results.

One works with preprocessing and settlement system units “Polygon”. One can process and analysis simulation results.

388



Modeling of thermal properties of the foundry mold in system “Polygon”.

One simulates the thermal properties of the foundry mold in the system “Polygon”.

One simulates the thermal properties of the foundry mold in the system “Polygon”.


Simulation of hydrodynamics of filling a foundry mold. One simulates the hydrodynamics of filling the foundry mold.

One simulates the hydrodynamics of filling the foundry mold.

Topic 8. Models of porosity formation in modeling system “Polygon”

Basic principles of solving the problem of the formation of macro- and micro-porosity in the modeling system “Polygon”. The sequence of computer modeling of porosity in the system “Polygon” .Visual view of parameters.

One solves the problems of formation of macro- and micro-porosity in the modeling system “Polygon”.

One explains the principles of solving the problem of formation of macro- and micro-porosity in the modeling system “Polygon”. One sets out the sequence of computer modeling of porosity in the system “Polygon”, visual representation of the parameters.


Simulation of macro-porosity formation in the casting in the system “Polygon”.

One stimulates macro-porosity formation in the casting in the system

One can stimulate macro-porosity formation in the casting in the system “Polygon”.

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“Polygon”.


Simulation of micro-porosity formation in the casting in the system “Polygon”.

One stimulates micro-porosity formation in the casting in the system “Polygon”.

One can stimulate micro-porosity formation in the casting in the system “Polygon”.

Topic 9. The deformation model in the system “Polygon”

Foundry casting defects. The ways and methods of its prevention. The calculation process of warping, dimensional accuracy, crystallization and formation of cold cracks.

One characterizes the deformation model in the “Polygon” system.

One describes foundry casting defects, ways and methods of its prevention. One explains calculation process of warping, dimensional accuracy, crystallization and formation of cold cracks.


The calculation process of warping, dimensional accuracy, crystallization and formation of cold cracks.

The calculation of process of warping, dimensional accuracy, crystallization and formation of cold cracks.

One performs the calculation process of warping, dimensional accuracy, crystallization and formation of cold cracks.

Topic 10. Thermodynamics and kinetics of cast iron crystallization: computer analysis

Computer analysis of the formation of structure of cast One describes One can explain computer analysis of the

390


iron. Conditions of formation and growth of centers of crystallization.

thermodynamics and kinetics of cast iron crystallization: computer analysis.

formation of structure of cast iron and determine conditions of formation and growth of centers of crystallization.

Topic 11. Professional system of computer modeling of casting processes “ProCAST”

The main units of the system “ProCAST”. The abilities of modeling system of foundry processes. Features of modeling performance of foundry processes with the special methods and casting in single sand-clay molds of iron-carbon and non-ferrous metals and alloys.

One describes the professional system of computer modeling of casting processes “ProCAST”.

One describes the main units of the system “ProCAST”. One shows the abilities of modeling system of foundry processes and sets out features of modeling performance of foundry processes with the special methods and casting in single sand-clay molds of iron-carbon and non-ferrous metals and alloys.


Working with unit MeshCAST. Working with unit MeshCAST.

One performs work with unit MeshCAST.


Working with unit PreCAST. Working with unit PreCAST.

One performs work with unit PreCAST.


Working with unit DataCAST. Working with unit One performs work with unit DataCAST.

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DataCAST.


Working with unit ViewCAST. Working with unit ViewCAST.

One performs work with unit ViewCAST.


Working with unit Status. Working with unit Status. One performs work with unit Status.


Simulation of filling a foundry mold with metal. One simulates filling a foundry mold with metal.

One simulates filling a foundry mold with metal.


Analysis of the results of modeling and development of technology for the manufacture of high-quality castings in the “ProCAST”.

One analyses the results of modeling and development of technology for the manufacture of high-quality castings in the “ProCAST”

One analyses the results of modeling and development of technology for the manufacture of high-quality castings in the “ProCAST”

Topic 12. Innovative production processes of manufacture of foundry tooling

Rapid prototyping technology “Rapid Prototyping”. Laser stereo lithography. Technology of selective laser sintering and layered manufacturing facilities and etc.

One describes innovative production processes of manufacture of foundry

One describes rapid prototyping technology “Rapid Prototyping”, laser stereo lithography, technology of selective laser sintering and

392


tooling. layered manufacturing facilities and etc.

Topic 13. Modern technological processes for production of foundry tooling

Casting for “fast” consumable (burnt out) models, using SLS and InkJet technologies. Prospects for rapid prototyping for manufacturing models and foundry molds using SLS and InkJet technologies, three-dimensional printing technique.

One describes modern technological processes for production of foundry tooling.

One describes casting process for “fast” consumable (burnt out) models, using SLS and InkJet technologies. One can name prospects for rapid prototyping for manufacturing models and foundry molds using SLS and InkJet technologies, three-dimensional printing technique.

393

Guidelines

The following forms of organization of teaching are recommended in order to implement a training program on discipline “The systems of computer-aided design and simulation of foundry processes”: lectures, workshops, field trips, laboratory classes.




- Training students in improved technology and increase of issuance of castings in serial production;

- Development of gating system for single-cast advanced products in a short time without tooling.

The discipline “Computer-aided design and simulation of casting processes” based on the knowledge gained in the study of academic disciplines such as “Drawing”, “Theory and technology of casting production”, “Fundamentals of computer technology in the industry”.

The knowledge gained from the study of the discipline, is used to study the following disciplines:


- Automatic lines and systems;


In the study of module it is necessary to carry out the integration of academic disciplines to general professional and special cycles.

The control of this academic discipline provides for interim attestation the main forms of which are assessment paper, exam and tests.


394


- exam -1;



As a result of study of the discipline a student must know:

- modern systems of computer simulation of casting processes;

- the basis of simulation of casting processes in systems Topich “ProCAST”, “Polygon”, “LVMFlow” and etc.;

- the possibilities of integrated systems of design and engineering analysis of strength and structural dynamics;

- advanced rapid prototyping technology, designed for the manufacture of casting and modeling tooling;

а student must be able to:

– create three-dimensional solid model in CAD system;

- design a foundry mold;

- develop technological process with the use of simulation systems “ProCAST”, “Polygon”, “LVMFlow” and etc.;

- apply this knowledge in the design and development of the foundry tooling.

395

DESIGN OF RIGGING

The purpose of the study of the discipline is to develop the students' knowledge in the field of materials, design and technique of designing tooling for manufacturing castings.


Section, Topic

Number of hours

all including hours for laboratory

works

1 2 3

Introduction 1

Section 1. Development of technological process of manufacturing models

5 2

1.1. Classification of pattern tooling 1

1.2. The development of foundry and model guidance 4 2

Section 2. Design and making patterns 4

2.1. Making wood patterns 2

2.2. Construction of patterns made from polymers 2

Section 3. Master patterns 10 4

3.1. Materials for master patterns 2

3.2 Construction of master patterns 8 4

Section 4. Design of core boxes 18 8

4.1. Construction of collapsible core boxes 4 2

4.2. Construction of split core boxes 6 2

4.3. Constructions of split core boxes core-making machine 8 4

396

Section 5. Construction of foundry flasks 6 2

5.1. Types of foundry flasks 2

5.2. Design rules of foundry flasks 4 2

Section 6. Die-casting 27 14

6.1. Installation of compression molds 12 6

6.2. Design of shaping parts 6 4

6.3 Design of structural parts 6 4

6.4. Design of mechanisms of compression molds 2

Control work 1

Section 7. Gravity die casting 7 4

7.1. Installation of gravity die 1

7.2. Design of gravity die 6 4

Course project 24

Total 102 34

397



Introduction

The structure and content of the discipline “Design of rigging”. The purpose and objectives of the discipline. The role of the discipline in the formation of professional knowledge, skills of students. The source document for the design of tooling.

One provides general judgment based on content of the discipline “Design of rigging”, the purpose and objectives of the discipline, the role of the discipline in the formation of professional knowledge, skills of students.

One judges on content of the discipline “Design of rigging”, the purpose and objectives of the discipline, the role of the discipline in the formation of professional knowledge, skills of students. One names the source document for the design of tooling.

Section 1. Development of technological process of manufacturing models

Topic 1.1. Classification of pattern tooling

Classification of pattern tooling: by the nature of the material, by the process for the production of molds and cores, the size of the casting, by manufacturing precision and strength, by the complexity of the configuration of the casting, by the nature of the filling alloy.

One provides classification of pattern tooling: by the nature of the material, by the process for the production of molds and cores, the size of the casting, by manufacturing precision and strength, by the complexity of the configuration of the casting, by the nature of the filling alloy.

One can classify pattern tooling: by the nature of the material, by the process for the production of molds and cores, the size of the casting, by manufacturing precision and strength, by the complexity of the configuration of the casting, by the nature of the filling alloy.

Topic 1.2. The development of foundry and model guidance

398


The procedure for determining the parting plane model and the shape and position of the casting in the mold. Machining allowance and shrinkage of the alloy castings. Pattern drafts. The procedure for determining the contours of the cores. Core signs and their design. The design of the gating system.

One expounds the procedure of determining the parting plane model and the shape and position of the casting in the mold. machine processing allowance and shrinkage of the alloy castings, pattern drafts.

One describes the procedure for determining the parting plane model and the shape and position of the casting in the mold, machining allowance and shrinkage of the alloy castings, pattern drafts. One develops the procedure for determining the contours of the cores, core signs and their design. One determines the design of the gating system.


The development of foundry and model guidance. One develops foundry and model guidelines.

One performs the development of foundry and model guidance.

Section 2. Design and making patterns

Topic 2.1. Making wood patterns

The basic properties of wood. Wood drying: heat, high-frequency and liquid. Wood species used for the various elements of the patterns and core boxes. Determining the consumption of sawn timber.

One expounds basic properties of wood and wood drying: heat, high-frequency and liquid.

Description of wood models production stages.

One describes basic properties of wood and wood drying: heat, high-frequency and liquid. One names wood species used for the various elements of the patterns and core boxes and determines the

399


consumption of sawn timber.

Topic 2.2. Construction of patterns made from polymers

Making standard pattern. Making promotional model. Manufacture of industrial models. Materials for promotional models, working models and release agents.

One expounds the procedure of making standard pattern, making reference models and manufacturing of industrial models.

One sets out the procedure of making standard pattern, making promotional model, of manufacture of industrial models and names materials for promotional models, working models and release agents.

Section 3. Master patterns

Topic 3.1. Materials for master patterns

Equipment and tools for processing models. Classes of dimensional accuracy. The roughness of the surface of the models.

One describes classes of materials used for the production of metal molds and equipment and tools used for the processing of metal molds.

One describes equipment and tools for processing models and explains classes of dimensional accuracy, the roughness of the surface of the models.

Topic 3.2. Construction of master patterns

The concept of promotional model. Construction of elements of the application of the model to the molding plates. Selection of the wall thickness of the model. The stiffening ribs and their design. Construction of detachable parts and core

One describes the peculiarities of metal molds construction.

One defines concept of promotional model, explains construction of elements of the application of the model to the molding plates. One describes selection of the wall thickness of the model, the stiffening ribs

400


characters. and their design, construction of detachable parts and core characters.


Designing of master patterns. One designs metal molds. One designs master patterns.

Section 4. Design of core boxes

Topic 4.1. Construction of collapsible core boxes

Collapsible core boxes with and without insets. Fixation of inserts in the body of core box. Locking of inserts together. The design of the case construction of collapsible core boxes. Stiffening ribs. The armored cover. Flanging.

One describes the peculiarities of collapsible core boxes structure.

One explains construction of collapsible core boxes and shows ways of fixing inserts.


Design of collapsible core boxes. One designs collapsible core boxes. One designs collapsible core boxes.

Topic 4.2. Construction of split core boxes

Boxes with vertical and horizontal plane of the connector. Fixing parts of box together. Opened and closed core boxes.

One describes the structure of split core boxes.

One describes constructions of split core boxes and ways of fixing separate parts together.


401


Designing of split core boxes. One designs split core boxes. One designs split core boxes.

Topic 4.3 Constructions of split core boxes of core-making machine

Core boxes for air sand blowers, their design and main elements. Core boxes for core sand shooters, their design and the basic elements. Construction and procedure of design of heated core boxes.

One describes the structure of core boxes for core machines.

One describes constructions and main elements of core boxes for core machines. One poses the procedure of designing of heated core boxes.


Designing of core boxes for core machines. One designs core boxes for core machines.

One designs core boxes for core machines.

Section 5. Construction of foundry flasks

Topic 5.1. Types of foundry flasks

Types of foundry flasks, scope of their application. Special constructions of foundry flasks. Requirements for choice of foundry flasks.

One describes types of foundry flasks, scope of their application and special varieties of foundry flasks’ structure.

One describes types of foundry flasks, scope of their application, Special constructions of foundry flasks and shows requirements for choice of foundry flasks.

Topic 5.2. Design rules of foundry flasks

Standard cast iron of foundry flasks. Sizing of flasks. Construction of walls of the foundry flasks.

One describes design rules of steel One describes design rules of steel and cast

402


Centering and guiding pins and plugs. Elements of fastening flasks. Steel cast and welded flasks.

and cast iron foundry flasks. iron foundry flasks.


Design of foundry flasks. One designs foundry flasks. One designs foundry flasks.

Section 6. Die-casting

Topic 6.1. Installation of compression molds

Classification of compression molds. Shaping parts and structural details. Mechanisms of compression molds.

One describes the compression-mold equipment structure.

One classifies compression molds, describes shaping parts and structural details, mechanisms of compression molds.


Study of setting of compression molds under die casting.

One researches compression-mold equipment under pressure.

One analyses setting of compression molds under die casting.

Topic 6.2. Design of shaping parts

Purpose and types of shaping parts of compression molds. Inserts, matrix, blanks, bushes, distributors, knockout pins, cores, their calculation.

One expounds purpose and types of shaping parts of compression molds, the calculation procedure of inserts, matrix, blanks, bushes, distributors, knockout pins and cores.

One name purpose and types of shaping parts of compression molds and explains the calculation procedure of inserts, matrix, blanks, bushes, distributors, knockout pins, cores, and their calculation.


403


Designing of shaping parts of a compression mold. One designs shaping parts of a compression mold.

One designs shaping parts of a compression mold.

Topic 6.3. Design of structural parts

Purpose and types of structural parts of a compression mold. Base plates, step plates, cover dies, bars, core plates, and their calculation.

One describes purpose and types of structural parts of compression molds and expounds the calculation procedure of base plates, step plates, cover dies, bars, core plate.

One name purpose and types of structural parts of compression molds and explains the calculation procedure of base plates, step plates, cover dies, bars, core plate.


Designing of structural parts of a compression mold.

One designs structural parts of a compression mold.

One designs structural parts of a compression mold.

Topic 6.4. Design of mechanisms of compression molds

Core drawing mechanisms. Mechanisms with kinematic and a separate drive locking.

One describes the design procedure of core drawing mechanisms and mechanisms with kinematic and a separate drive locking.

One describes the design procedure of core drawing mechanisms and mechanisms with kinematic and a separate drive locking.

Control work

Section 7. Gravity die casting

404


Topic 7.1. Installation of gravity die

Classification of gravity dies. Materials for parts of gravity dies.

One describes classification of gravity dies and materials for parts of gravity dies.

One describes classification of gravity dies and name materials for parts of gravity dies.

Topic 7.2. Design of the gravity die

Calculation of the operation gravity die. Centering the parts of the gravity die. Ventilation of cavity of gravity die.

One describes the gravity die’s design stages.

One explains calculation of the operation gravity die, centering the parts of the gravity die, ventilation of cavity of gravity die.


Designing of details of a gravity die. One designs gravity die parts. One designs details of a gravity die.

Course project

Design of tooling. The choice of material. Determining working sizes. Features of production. Performing calculations, drawing of production tooling.

Course project. While performing course project One designs tooling and carries out calculation, drawing of production tooling.

405

Guidelines

The following forms of organization of teaching are recommended in order to implement a training program on discipline “Design of rigging”: lectures, workshops, field trips, laboratory classes.




- Teaching students for design tooling;- Study of constructions, methods of calculating the basic parameters of

tooling. Discipline “Design of rigging” is based on the knowledge obtained in the

study of such disciplines as “Drawing”, “Computer-aided design systems and simulation of foundry processes".




-course project – 1;

-credit – 1;

- exam -1;



The knowledge gained from the study of the discipline, used to study the following modules:

406


- Foundry equipment;

- Theory and technology of foundry production.

In the study of the discipline it is necessary to carry out the integration of academic disciplines with general professional and special cycles.

As a result of study of the discipline a student must know:

- advanced materials and construction of tooling for the production of castings;

- methods of calculation of the main parameters of tooling;

- the distinctive features of design of tooling for hand and machine molding;

- designs of flasks for different molding machines and automatic lines;

- mechanisms of compression molds for die casting, their design and details, being parts of the mechanisms;

а student must be able to:

- analyze the manufacturability of parts for certain way of molding;

- design tooling and calculate its main elements;

- carry out drawings of various parts of equipment using standard packing applications.

407

AUTOMATIC LINES AND SYSTEMS

The aim of the program is formation of the students' knowledge in the field of new technical specifications, layout and design features of automatic lines and systems used in modern foundry production, control systems of automatic casting lines and automatic systems.


Section, Topic

Number of hours

all

including hours for laboratory

works

1 2 3

Introduction 1

Section 1. Methods of analysis, calculation and design of the automatic lines and systems

11 6

1.1. Basics of designing automatic lines 3 2

1.2. Control systems of automatic lines 4 2

1.3. Performance, reliability and efficiency 4 2

Section 2. Automatic casting lines 30 12

2.1. Automatic molding lines. Production of moulds by pressing methods

4 2

2.2. Automatic manufacturing line of forms by air pressing method (Seiatsu Process)

4 2

2.3. Automatic lines of flaskless molding 4 2

2.4. Automatic molding lines (AML) of pulse molding technique

2

2.5. Special automatic casting lines 2

408

1 2 3

2.6 AML of vacuum-film molding 4 2

2.7. Automatic line production of castings in the molds of the cold-hardening mixtures

4 2

2.8. Automated systems of chill casting and die casting 2

2.9. Automatic lines for casting using molded and burnt out models

4 2

Section 3. Automated batch-preparation equipment and systems of manufacturing cores

10 4

3.1. Equipment and automated production of system of cores 4 2

3.2. Automatic batch-preparation equipment 4 2

3.3. System of training and regeneration of molding sand 2

Section 4 Automatic systems for melting and teeming metal

16 8

4.1. Modern melting structures. The induction melting of metals

4 2

4.2. Complexes of electric-arc melting and secondary metal working

4 2

4.3. Automated cupola systems 4 2

4.4. Systems of preparation and dosing of charging materials 1

4.5. Mixers and filling devices 3 2

Section 5. Automation of finishing operations of manufacturing castings

5 2

5.1. Finishing operations of making castings 1

5.2. Equipment and automated systems for the finishing operations

3 2

Control work 1

409

1 2 3

Section 6. Disposal systems of heat of furnace gas and dust and gas cleaning of foundry shops

2

6.1. Heat recovery of flue gases aspirated from the melting and heating furnaces

1

6.2. Cleaning Systems of dust and gas emissions 1

Total 75 32

410



Introduction

The structure and content of the discipline “Automatic lines and systems". The purpose and objectives of the course. The role of the discipline in the formation of professional knowledge and students’ skills. Challenges of automation and control of technological processes and equipment in foundry shops. The advantages and disadvantages of the automatic casting lines (ACL).

One expresses general judgment on the contents of the subject “Automatic lines and systems", purpose and objectives of the course, role of the subject in the formation of professional knowledge and skills.

One judges on о content of the discipline “Automatic lines and systems". The purpose and objectives of the course. The role of the discipline in the formation of professional knowledge and students’ skills. One can name challenges of automation and control of technological processes and equipment in foundry shops, also advantages and disadvantages of automatic casting lines (ACL).

Section 1. Methods of analysis, calculation and design of the automatic lines and systems

Topic 1.1. Basics of designing automatic lines

Basic concepts and definitions of automatic lines and systems. Classification of the ACL. Composition and layout of the ACL. Analysis and optimization of structure of the ACL. The features of design and production of the ACL.

One expounds the basics of automatic lines design.

One states basic concepts and definitions of automatic lines and systems, describes classification of ACL, composition and layout of ACL, analysis and optimization of structure of ACL, features of design and production of ACL.


411


The study of composition, layout and structure of the ACL.

One researches composition, layout and structure of ACL.

One analyses composition, layout and structure of ACL.

Topic 1.2. Control systems of automatic lines

Control systems of the ACL. Classification of control systems. The features of construction and typical structure of control systems of the ACL.

One describes automatic lines’ control systems.

One describes classification of control systems. Features of construction and typical structure of control systems of ACL.


The study of construction and typical structures and management systems of the ACL.

One researches construction and typical structures and management systems of ACL.

One analyses construction and typical structures and management systems of ACL.

Topic 1.3. Performance, reliability and efficiency

Performance of the ACL. The reliability and efficiency of the ACL. The ACL interaction with the adjacent equipment. The ways to improve the efficiency, reliability of the ACL.

One discusses performance of ACL, the reliability and efficiency of ACL, the ACL interaction with the adjacent equipment.

One discusses performance of ACL, the reliability and efficiency of ACL, the ACL interaction with the adjacent equipment and names the ways to improve the efficiency, reliability of ACL.


Study of the ACL interaction with the adjacent One researches the ACL interaction One analyses the ACL interaction with the

412


equipment. with the adjacent equipment. adjacent equipment.

Section 2. Automatic casting lines

Topic 2.1. Automatic molding lines. Production of moulds by pressing methods

Classification of the automatic molding lines (AML). Structure and design principles of AML. The lines of flask molding, accessories and transport of AML. Compression molding, varieties of the method, advantages and disadvantages.

One describes classification of automatic molding lines (AML), structure and design principles of AML, the lines of flask molding, accessories and transport of AML.

One describes classification of automatic molding lines (AML), structure and design principles of AML, the lines of flask molding, accessories and transport of AML and explains compression molding, varieties of the method, advantages and disadvantages


The study of structure and the operating principle of the AML.

One researches the structure and the operating principle of the AML.

One analyses structure and the operating principle of the AML.

Topic 2.2. Automatic manufacturing line of forms by air pressing method (Seiatsu Process)

The advantages and disadvantages of making molds by air-pressing method (Seiatsu Process). The process scheme. The organization of lines for the manufacture of molds to Seiatsu Process.

One explains the advantages and disadvantages of making molds by air-pressing method (Seiatsu Process).

One explains the advantages and disadvantages of making molds by air-pressing method (Seiatsu Process), the process scheme and describes the organization of lines for the manufacture of molds to Seiatsu Process.

413



The study of the structure and mode of operation of automatic molding lines according to Seiatsu Process.

One researches the structure and mode of operation of automatic molding lines according to Seiatsu Process.

One analyses the structure and mode of operation of automatic molding lines according to Seiatsu Process.

Topic 2.3. Automatic lines of flaskless molding

Air sand blower and sand-shooter methods of molding. Process scheme. The advantages and disadvantages of the method.

One describes automatic lines of flaskless molding.

One describes Air sand blower and sand-shooter methods of molding and explains process scheme and the advantages and disadvantages of the method.


The study of the structure and mode of operation of automatic flaskless vertical molding lines.

One researches structure and mode of operation of automatic flaskless vertical molding lines.

One analyses the study of the structure and mode of operation of automatic flaskless vertical molding lines.

Topic 2.4. Automatic molding lines (AML) of pulse molding technique

Classification and variations of methods of pulse molding. Organization of automatic lines of impulse molding. Operating principles of impulse molding machines. The advantages and disadvantages of pulsed methods.

One describes classification and variations of methods of pulse molding, organization of automatic lines of impulse molding.

One reveals classification and variations of methods of pulse molding, organization of automatic lines of impulse molding and describes operating principles of impulse molding machines, advantages and

414


disadvantages of pulsed methods.

Topic 2.5. Special automatic casting lines

Continuous horizontal and vertical casting, centrifugal casting, molding by freezing, magnetic forming. Technology features of methods. The organization of automatic transfer lines and automated systems for making castings by special methods.

One describes continuous horizontal and vertical casting, centrifugal casting, molding by freezing, magnetic forming.

One discusses continuous horizontal and vertical casting, centrifugal casting, molding by freezing, magnetic forming, technology features of methods and describes the organization of automatic transfer lines and automated systems for making castings by special methods.

Topic 2.6. AML of vacuum-film molding

Technique of vacuum-film molding. The advantages and disadvantages of the method. The organization of AML of vacuum-film molding.

One researches the technique of vacuum-film molding.

One explains technique of vacuum-film molding, names the advantages and disadvantages of the method and describes the organization of AML of vacuum-film molding.


The study of the structure and mode of operation of automatic lines of vacuum-film forming.

One analyses the study of the structure and mode of operation of automatic lines of vacuum-film

One analyses the study of the structure and mode of operation of automatic lines of vacuum-film forming.

415


forming.

Topic 2.7. Automatic line production of castings in the molds of the cold-hardening mixtures

The cold-hardening mixtures (CHM) used on the AML, the advantages and disadvantages of manufacturing castings in forms of CHM. The organization of the automatic lines of making molds from CHM.

One describes automatic line production of castings in the molds of the cold-hardening mixtures.

One describes cold-hardening mixtures (CHM) used on the AML, the advantages and disadvantages of manufacturing castings in forms of CHM, organization of the automatic lines of making molds from CHM.


The study of the structure and mode of operation of the automatic lines for the manufacture of molds and cores from liquid glass mixtures.

One analyses the structure and mode of operation of automatic lines for the manufacture of molds and cores from liquid glass mixtures.

One analyses the structure and mode of operation of automatic lines for the manufacture of molds and cores from liquid glass mixtures.

Topic 2.8. Automated systems of chill casting and die casting

The advantages and disadvantages of the manufacture of metal castings in molds. The organization of the automated systems in chill casting. The methods of die casting, machines and automated pressure systems of die casting.

One characterizes automated systems of chill casting and die casting.

One names the advantages and disadvantages of the manufacture of metal castings in molds, describes the organization of automated systems in chill casting, and reveals methods of die casting, machines and automated pressure systems

416


of die casting.

Topic 2.9. Automatic lines for casting using molded and burnt out models

The structure and organization of the automated systems for casting using molded models. The advantages and disadvantages of the method of casting using molded models. Modern modular automated complexes of casting using burnt out models. The advantages and disadvantages of the complexes of casting using burnt out models.

One expounds structure and organization of the automated systems for casting using molded and burnt out models.

One describes structure and organization of the automated systems for casting using molded and burnt out models and names advantages and disadvantages of the methods.


The study of the structure and mode of operation of the automated systems for casting using molded and burnt out models.

One recreates a model of the structure and analyses mode of operation of the automated systems for casting using molded and burnt out models.

One analyses the structure and mode of operation of the automated systems for casting using molded and burnt out models.

Section 3. Automated batch-preparation equipment and systems of manufacturing cores

Topic 3.1. System of training and regeneration of molding sand

The main methods of manufacturing cores. Core machines. Organization of automated complexes and systems of automatic manufacturing rods.

One describes core manufacturing equipment and automatic systems.

One explains the main methods of manufacturing cores, describes core machines and organization of automated

417


complexes and systems of automatic manufacturing rods.


The study of the structure and mode of operation of automatic lines and machines for manufacturing and coloring cores.

One recreates the model of the structure and analyses mode of operation of automatic lines and machines for manufacturing and coloring cores.

One analyses the structure and mode of operation of automatic lines and machines for manufacturing and coloring cores.

Topic 3.2. Automatic batch-preparation equipment

Modern methods of batch-preparation. Automatic methods of quality control of foundry sands. Classification of mixers. Organization of the automated systems of batch-preparation.

One expounds methods of batch-preparation and automatic methods of quality control of foundry sands.

One reveals modern methods of batch-preparation, automatic methods of quality control of foundry sans and describes classification of mixers, organization of automated systems of batch-preparation.


The study of the structure and mode of operation of automatic systems of batch-preparation quality control of foundry sands.

One recreates the model of the structure and analyses mode of operation of automatic systems of batch-preparation quality control of foundry sands.

One analyses the structure and mode of operation of automatic systems of batch-preparation quality control of foundry sands.

418


Topic 3.3. System of training and regeneration of molding sand

Methods for regeneration of molding and core sands. Recovery of properties of the waste system sand. Methods for wet and dry recovery, the advantages and disadvantages.

One explains the system of preparation and reclamation of molding sands.

One explains methods for regeneration of molding and core sands and describes recovery of properties of the waste system sand, methods for wet and dry recovery, the advantages and disadvantages

Section 4. Automatic systems for melting and teeming metal

Topic 4.1. Modern melting structures. The induction melting of metals

Classification of induction melting furnaces. The composition of the modern smelting complex. Monitoring, control and safety systems of melting in induction furnaces. Methods of intensification of induction melting.

One describes modern melting structures and induction metal melting.

One describes classification of induction melting furnaces, the composition of the modern smelting complex, monitoring, control and safety systems of melting in induction furnaces, methods of intensification of induction melting.


The study of the structure and mode of operation of automatic melting systems.

One recreates a model of the structure and analyses the mode of operation of an automatic melting system.

One analyses the structure and mode of operation of automatic melting systems.

Topic 4.2. Complexes of electric-arc melting and secondary metal working

419


Classification of electric arc furnaces. The methods of intensification of electric arc furnaces and melt processing techniques. Modern melting systems based on electric arc furnaces.

One shows classification of electric arc furnaces, methods of intensification of electric arc furnaces and melting processing techniques.

One shows classification of electric arc furnaces, methods of intensification of electric arc furnaces and melting processing techniques and describes modern melting systems based on electric arc furnaces.


The study of the structure and mode of operation of modern melting systems based on electric arc furnaces.

One recreates a model of the structure and analyses the mode of operation of modern melting systems based on electric arc furnaces.

One analyses the structure and mode of operation of modern melting systems based on electric arc furnaces.

Topic 4.3. Automated cupola systems

Classification of cupola installations. Modern automated cupola systems. Methods to improve the technical and environmental parameters of cupola melting. The systems of automatic control of cupola.

One describes automated cupola systems.

One describes classification of cupola installations, modern automated cupola systems, explains methods to improve the technical and environmental parameters of cupola melting, systems of automatic control of cupola.


The study of the structure and mode of operation One recreates a model of the One analyses the structure and mode of

420


of automated cupola systems. structure and analyses the mode of operation of automated cupola systems.

operation of automated cupola systems.

Topic 4.4. Systems of preparation and dosing of charging materials

Basic requirements for the charge materials. The methods for preparation of the raw materials and the use of the automated systems for preparation, dosing and loading charge materials in the melting furnace. Heating systems for metallic charge.

One expounds basic systems of preparation and dosage of charging materials.

One develops basic requirements for the charge materials. Methods for preparation of the raw materials and the use of the automated systems for preparation, dosing and loading charging materials in the melting furnace and describes heating systems for metallic charge.

Topic 4.5. Mixers and filling devices

Equipment for the holding and pouring metal into molds. Automatic casting devices. Control systems and process control of pouring.

One describes equipment for the holding and pouring metal into molds, automatic casting devices, control systems and process control of pouring.

One describes equipment for the holding and pouring metal into molds, automatic casting devices, control systems and process control of pouring.


The study of the structure and mode of operation of automatic casting devices.

One recreates a model of the structure and analyses the mode of operation of automated casting

One analyses the structure and mode of operation of automatic casting devices.

421


systems.

Section 5. Automation of finishing operations of manufacturing castings

Topic 5.1. Finishing operations of making castings

Cropping of iron and steel castings. Shot-blasting. Foundry grinding. The methods of quality control of castings and correction of casting defects. Automation of finishing operations in the mass production of the castings.

One expounds the finishing operations of making castings.

One describes cropping of iron and steel castings, shot-blasting, foundry grinding and explains methods of quality control of castings and correction of casting defects, automation of finishing operations in the mass production of the casting.

Topic 5.2. Equipment and automated systems for the finishing operations

Robots and manipulators for knockout of casting. Control systems. Equipment and automated systems for cropping, blasting and cleaning of castings of non-ferrous alloys. Automatic control units for surface cleaning of castings.

One describes equipment and automated systems for the finishing operations.

One describes control systems robots and manipulators for knockout of casting equipment and automated systems for cropping, blasting and cleaning of castings of non-ferrous alloys and names automatic control units for surface cleaning of castings.


The study of the structure and mode of operation of automatic systems and devices of quality

One researches the structure and mode of operation of automatic

One analyses the structure and mode of operation of automatic systems and devices

422


control of castings. systems and devices of quality control of castings.

of quality control of castings.

Control work

Section 6. Disposal systems of heat of furnace gas, dust, gas and cleaning foundry shops

Topic 6.1. Heat recovery of flue gases aspirated from the melting and heating furnace

Methods of disposal of secondary energy resources. Convective and radioactive heat exchangers. Heat recovery systems of fuel melting and heating furnaces.

One characterizes systems of heat recovery of flue gases aspirated from the melting and heating furnace.

One describes methods of disposal of secondary energy resources and judges on convective and radioactive heat exchangers, heat recovery systems of fuel melting and heating furnaces.

Topic 6.2. Cleaning systems of dust and gas emissions

Classification of methods and systems for gas treatment. Methods and systems of automatic control of air emissions. Schematic diagrams of the construction of the integrated systems of gas treatment.

One describes the classification of methods and systems of cleaning of dust and gas emissions.

One discusses classification of methods and systems for gas treatment and describes methods and systems of automatic control of air emissions, schematic diagrams of the construction of the integrated systems of gas treatment

423

Guidelines

The following forms of organization of teaching are recommended in order to implement a training program on discipline “Automatic lines and systems”: lectures, workshops, field trips, laboratory classes.




- teaching students for the structure, composition and technological capabilities of the automated systems, automated lines and systems;

- study of process diagrams, advantages and disadvantages of casting methods, the organization of automatic transfer lines and automated systems for making castings.

Discipline “Automatic lines and systems” is based on the knowledge gained from studying such disciplines as “Automation of foundry production”, “Equipment of foundry shops”.

The knowledge gained from the study of the unit used in the study of following units:

- Theory and technology of foundry production;


In the study the unit it is required to carry out integration with the academic disciplines of general professional and special cycles.




424

-course project – 1;

- exam -1;



A study of academic disciplines a student must know:

- principles of construction and development of automated systems, automated lines and systems;

- the main technical characteristics, layout and design features of automated lines and systems used in modern foundry production;

- the organization of automatic transfer lines and automated equipment for molding castings of special methods;

- the methods of calculation and estimation of basic economic, technological, and exploitation parameters of automated lines and systems;


- analyze the structure, composition and technological capabilities of automated-bath complexes, automated lines and systems;

- assess economic, technological and technical parameters of the automated lines and systems;

- calculate and design automated systems, automatic lines and systems for the implementation of the basic processes of foundry production.

425

AUTOMATION OF FOUNDRY PRODUCTION

The purpose of the study of the discipline is to prepare students for practice in today's highly mechanized and automated foundry shop.


Section, Topic

Number of hours

allIncluding for

practical works

Introduction 2

Section 1. The information about automation and its elements.

14

1.1 Automatic control, monitoring and regulation of industrial processes. Automation Systems

2

1.2. Automatic control system 2

1.3. Systems for automatic control, regulation, remote control, automatic protection and block

2

1.4. Converters, executive devices and regulators in automation

8

Section 2. Control and measuring devices in the automated systems of foundry production

40 16

2.1. Temperature measurement 8 4

2.2. Pressure and differential pressure 6 2

2.3. Flow measurement and dosing of liquids, gases and granular materials

8 4

2.4. Measuring the level of bulk and liquid materials 6 2

2.5. Measurement of moisture and gas materials 6 2

2.6 Measurement of gas composition 6 2

Section 3. Automation systems of foundry production 30 18

426

3.1 Automation of the process of cores making 6 4

3.2 Automation of making molds and cores 6 4

3.3. Metal melting and casting 4 2

3.4 Shacking-out, fettling and cleaning of casts 6 4

3.5 Automation of special types of casting 5 4

Control work 1

3.6 Methods and tools for the automatic control of the environment

2

Total 86 34

427


Contents of the topic Results

Introduction

The goals and objectives of the course subject. The value and effectiveness of the automatic control, monitoring and control of production processes. Automation as a basis for technical progress.

One expresses an overall judgment on the content of the discipline “Automation of foundry production”.

One expresses an overall judgment on the content of the discipline “Automation of foundry production”, the purposes, objectives and role of the discipline in the formation of professional knowledge and skills.

SECTION 1. The information about automation and its elements.

Topic 1.1. Automatic control, monitoring and regulation of industrial processes. Automation Systems.

Basic concepts and definitions of automation in the foundry industry. Details of automation systems and their elements. Devices of automatic regulation, remote control, automatic protection and block. Local automation systems, integrated and automated. Elements of automation systems as energy converters, static and dynamic characteristics of elements feedbacks.

One reveals the basic concepts and definitions of automation in the foundry industry and describes local automation systems.

One reveals the basic concepts and definitions of automation in the foundry industry. One analyzes local automation systems, integrated and automated. One characterizes the elements of automation systems as energy converters, static and dynamic characteristics of elements feedbacks.

Topic 1.2. Automatic control system.The automatic control system (ACS). Basic concepts and definitions. The object of

One describes the object of regulation, outrage,

One describes the object of regulation, outrage, misalignment, adjustable parameter that regulates

428


regulation, outrage, misalignment, adjustable parameter that regulates the energy load on the subject of regulation, automatic control device. Closed and opened ACS, functional and structural schemes of the ACS, sustainability and quality of the ACS. Classification of regulators.

misalignment, adjustable parameter, etc.

energy load on the object of regulation, automatic control device. One classifies regulators and describes the opened and closed ACS and functional block diagram of the ACS, the stability and quality of the ACS.

Topic 1.3 Systems for automatic control, regulation, remote control, automatic protection and block.The systems of automatic control and alarm. Remote transmission systems and tracking systems. Automatic and non-automatic machinery, unbalanced and balanced. Signaling converters of relay action. Remote electrical transmission analog current and analog voltage. Pneumatic, hydraulic, electro-hydraulic and pneumatic remote transmission. Continuous automatic systems of synchrotransmission

One characterizes systems for automatic control, regulation, remote control, automatic protection and block.

One describes the automatic control system and alarm, telemetry and tracking systems. One classifies signaling converters of relay action, remote electrical transmission analog current and analog voltage. One characterizes the pneumatic, hydraulic, electro-hydraulic and pneumatic remote transmission.

Topic 1.4. Converters, executive devices and regulators in automation.A switchgear and a system control valve of electrics. Packet switches, plugs, limit switches and circuit breakers, relays, contactors,

One expounds characteristics and purpose of converters, executive devices and

One describes electric, magnetic, pneumatic, hydraulic and mechanical amplifiers of automation and their characteristics. One names and characterize contact, rheostat, strain gauge,

429


magnetic starters, command and other devices.

The actuators. The actuators electrical, electromagnetic, hydraulic and pneumatic. Regulatory bodies. Primary converters, amplifiers and stabilizers. Transducers analog, digital and frequency; electrical, pneumatic, hydraulic. Electric, magnetic, pneumatic, hydraulic and mechanical amplifiers of automation and their characteristics. Electric, pneumatic and hydraulic stabilizers.

Hydro (pneumatic) mechanical converters: elastic (diaphragm, bellows, tubular) and float. Mechanical and electrical converters. Contact, rheostat, strain gauge, inductive, capacitive, electrochemical and electrets converters.

regulators in automation. inductive, capacitive, electrochemical and electrets converters. One uses the electrical, electromagnetic, hydraulic and pneumatic actuators and defines regulatory bodies.

Section 2. Control and measuring devices in the automated systems of foundry production

Topic 2.1. Temperature measurement.Expansion thermometers (liquid-glass, bimetal and dilatometric), pressure thermometers (manometric thermometers), resistance thermometers; thermocouple thermometers; radiation pyrometers. A ratiometer, bridge

One explains the purpose and operation mode of different types of thermometers.

One describes types and operation principle of thermometers. Names the area of their application.

430


expansion joints, pyrometric millivoltmeters. Bright and color radiation pyrometers.


Temperature measurement of materials by resistance thermometers.

Calculation of materials’ temperature with resistance thermometers.

One measures and calculates the temperature of the materials by means of resistance thermometers.


Temperature measurement of materials by thermoelectric thermometers.

Calculation of materials’ temperature with thermoelectric thermometers.

One measures and calculates the temperature of the materials by means of thermoelectric thermometers

Topic 2.2. Pressure and differential pressure.Differential of pressure and pressure measurement methods. Strain manometers (technical, recording, with an electric differential-transformer system) and liquid manometers. Draft gauges and U-tube manometers (liquid and deformation). Liquid, spring, compensation, reciprocating differential manometers.

One expounds the description and application of strain manometers, draft gauges and U-tube manometers, liquid, spring, compensation, reciprocating differential manometers.

One operates pressure varieties and methods of measurement. One describes and uses strain manometers, draft gauges and U-tube manometers, liquid, spring, compensation, reciprocating and differential manometers.

Practical work No. 3Pressure measurement in liquids and gases. One measures pressure in

liquids and gases.One measures pressure in liquids and gases.

431


Topic 2.3. Flow measurement and dosing of liquids, gases and granular materials.The methods of variable pressure drop and constant pressure drop. Flow meters with manual and automatic action. Electromagnetic variable flow meters. Counters consumption. Dispensers.

One describes flow measurement and dosage of liquids, gases and granular materials.

One explains the methods of variable pressure drop and constant pressure drop. One characterizes the flow meters, variable flow meters and dispensers.


Flow measurement of liquid and gaseous materials with flow meters of variable constant pressure.

One measures the flow of liquid and gaseous materials with flow meters of variable constant pressure.

One performs flow measurement of liquid and gaseous materials with flow meters of variable constant pressure.

Topic 2.4. Measuring the level of bulk and liquid materialsMeasuring the level of bulk and liquid materials. Conductivity, capacitive (inductive) and radioactive detectors.

One describes the method of measuring the level of bulk and liquid material.

One analyzes the methods of measurement of bulk and liquid materials. One characterizes conductivity, capacitive (inductive) and radioactive detectors.


Level control of liquid and bulk materials. Level control of liquid and bulk materials.

Level control of liquid and bulk materials.

Topic 2.5. Measurement of moisture and gas materials.

432


Measurement of moisture and gas materials. Psychometric, hygroscopic, chloride-lithnic moisture meters. Control of mold ability (flow ability).

One describes the measurement of moisture of gas and materials.

One explains the concept of humidity of the gas and materials. One characterizes a psychometric hygrometer, hygroscopic, chloride-lithnic moisture meters, control the mold ability (flow ability).


Measurement of gas humidity with psychrometric hygrometer.

One measures gas humidity with a psychrometric hygrometer.

One carries measurement of gas humidity with psychrometric hygrometer.

Topic 2.6. Measurement of the density of liquids.The methods for measuring the composition of the gases. Automatic gas analyzer (thermoconductometric, thermo chemical, magnetic, optical).

One expounds the means of measuring density of liquids.

One sets out the methods for measuring the composition of the gases and describes automatic gas analyzers.


Control of gas composition by thermal conductivity and thermo chemical gas analyzers.

Monitoring of gas composition with thermoconductometric and thermo chemical analyzers.

One conducts monitoring and analysis of the thermal conductivity of gases and thermo chemical gas analyzers.

Section 3. Automation systems of foundry production

Topic 3.1 Automation of the process of cores makingAutomating the process of preparation of sand. Automating the process of recycling the spent

One describes automation of One describes the automation of the process of preparation of sand. One characterizes the features

433


sand by dry method. Automation of the processes of dry mechanical and hydraulic regeneration of foundry sand. Automating the process of preparation of clay and coal slurry. Automation of the batch mixer. Automation of the continuous mixer.

the process of cores making. of the automated batch mixer, continuous mixer automation.


Humidity measurement of molding compounds of conductometric moisture meter.

One measures foundry sand humidity with conductometric hygrometer.

One takes measurements of moisture forming mixes by conductometric hygrometer.

Topic 3.2 Automation of making molds and coresAutomation of the press and jar molding machine. The principles of automation of sand shooter molding machine. Automation of air sand blower (sand shooter) machines. Automation of installations for drying the molds and cores including gas heating.

One describes the automation of the press and jar molding machines, the automation of molds and cores manufacturing processes.

One describes automation of the press and jar molding machine. One characterizes the principles of automation of sand shooter molding machine. One describes automation of air sand blower machines, automation of installations for drying the molds and cores including gas heating.


Studying of automation of the processes of preparation of molding materials.

One calculates the level of automation of the foundry mold materials’ preparation.

One calculates automation of the processes of preparation of molding materials.

434


Topic 3.3. Metal melting and castingAutomating the process of loading the cupola, induction and electric arc furnace. Automating the process of melting metal in the cupola, induction and electric arc furnace. Automating the process of filling forms on the foundry line production.

One characterizes the description of the process of metal melting and casting.


Automation of the processes of melting metals One calculates automation of the processes of melting metals.

One calculates automation of the processes of melting metals.

Topic 3.4 Shacking-out, fettling and cleaning of castsAutomating the process of loading the cupola, induction and electric arc furnace. Automating the process of melting metal in the cupola, induction and electric arc furnace. Automating the process of filling forms on the foundry line

One describes the process knock-out, fettling and cleaning of casts.

One describes the automation of the loading process of cupola and electric induction furnace. One characterizes the process of melting metal in the cupola, induction and electric arc furnace. One communicates automation of filling forms on the foundry line.


Automation of the processing finished castings. One calculates automation of the processing finished castings.

One calculates automation of the processing finished castings.

435


Topic 3.5 Automation of special types of castingAutomation of the chill casting machine. Automation of the injection molding machines under high and low pressure.

One describes the automation of special types of casting.

One describes automation of the chill casting machine and the injection molding machines under high and low pressure.


Studying of automation of a single-position chill casting machine.

One calculates automation of a single-position chill casting machine.

One calculates automation of a single-position chill casting machine.


Studying of automation low and high pressure casting machinery.

One calculates automation low and high pressure casting machinery.

One calculates automation low and high pressure casting machinery.

Control workTopic 3.6 Methods and tools for the automatic control of the environment

Organization of sampling of dusty environment of the gas, requirements for a gas sample. The methods for measuring the dust content in the gases. Scheme of measuring system for determining the absolute removal of dust. The methods of automated microanalysis of wastewater.

One characterizes methods and tools for the automatic control of the environment.

One characterizes the organization of sampling of dusty environment of the gas. One describes the requirements for a gas sample. One sets out methods for measuring the dust content in gases and analyzes circuit measuring system for determining the absolute removal of dust. One operates the method of the automated

436


microanalysis of wastewater.

437

Guidelines

The following forms of organization of teaching are recommended in order to implement a training program on discipline “Automation of foundry production”: lectures, workshops, field trips, laboratory classes.



The main objectives of the academic discipline are:• systematic study of students information on the overall automation of

processes of foundry production on the basis of a wide range of modern technical means of automation and general purpose;

• preparation of students for practice in the modern foundry workshop equipped with mechanized and automated equipment.

The discipline is based on the knowledge gained in the study of such disciplines as “Drawing”, “Fundamentals of Technical Mechanics”, “Theory and Technology foundry production”, “Foundry equipment” and etc.

The control of this academic discipline provides for interim attestation the main forms of which are credit and tests.


- assessment paper;

- exam -1;



As a result of the study of the discipline a student must know:- devices for the automatic regulation of the remote control, automatic

protection and block;- units of converters and instrumentation for automated foundry production;A student must be able to:

438

- develop structural and functional scheme of automation of casting processes and equipment;

- design and develop structural and functional scheme of automation of casting processes and equipment.

439

List of training literature

№ Name AuthorPublishing

officeEdition number ISBN code

Place of publication

Date of publicati

on

Discipline (s) in which the book is

used

Total required amount

Com-ments

1. Theory and technology of foundry production. In 2 parts. Part 1. Molding materials and mixtures: a textbook

Kykyi D.M., SkvortsovV.A., Andrianov N.V.

Novoe znanie

INFRA-М, general

INFRA-М, part 1

978-985-475-327-0,

978-5-16-004761-4,

978-5-16-004762-1

Minsk

Moscow

2011 Theory and technology of foundry production. Construction and technological bases for production of cores at hand molding. Construction and technological bases for machine production of cores.

2. Theory and technology of foundry production. In 2 parts.Part 2. Technology of manufacture of castings in single forms: a textbook

Kykyi D.M., Skvortsov V.A., Andrianov N.V.

Novoe znanie

INFRA-М, general

INFRA-М, part 2

978-985-475-329-4,

978-5-16-004761-4

978-5-16-004787-4

Minsk

Moscow

2011 Theory and technology of foundry production.

Designing of equipment. Construction and technological bases for production of cores at hand molding. Construction and technological bases for machine

440




Date of publicati

on


used


Com-ments

production of cores

3. Theory and technology of foundry production

Kykyi D.M., Skvortsov V.A., Ektova V.N.

Design PRO 985-452-006-4 Minsk 2000 Theory and technology of foundry production. Designing of equipment. Automatic lines and systems

4. Moulding sandy-clayey mixtures

Kyzmin N.N. BSTU 5-89838-050-7 Bryansk 2002 Theory and technology of foundry production

5. Technology of foundry production

Chyrkin B.S., Gofman E.B.

USPPU 5-8050-0037-7 Ekaterinburg 2000 Theory and technology of foundry production

6. Theory and technology of foundry production. Molding materials and mixtures

Kykyi D.M.,Andrianov N.V.

BNTU 985-479-221-8 Minsk 2005 Theory and technology of foundry production

7. Fundamentals of technology of foundry production. Hand and machine production of molds and cores

Nekrasov G.B., Odarchenko I.B.

Vysheishayashkola

978-985-06-2558-8

Minsk 2015 Construction and technological bases for production of cores at hand molding. Construction and

441




Date of publicati

on


used


Com-ments

technological bases for machine production of cores

8. Foundry alloys Krutilin A.N., Nikolaychik Y.A.

BNYU 978-985-550-363-8

Minsk 2015 Foundry alloys and melting

9. Foundry alloys and melting. Production of castings from cast iron and steel.

Romanov L.M., Boldin A.N.

MSIU 5-276-00703-9 Moscow 2005 Foundry alloys and melting

10. Foundry molding materials. Molding, core mixtures and coatings: Directory

Boldin A.N. Mashinostroenie 5-217-03329-0 Moscow 2006 Foundry alloys and melting

11. Theory and technology of steel production

Kydrin V.А. Mir 5-03-003533-8 Moscow 2003 Foundry alloys and melting

12. Metallurgy of aluminum casting alloys

ZolotorevskiyV.S., Belov N.А.

Moscow Institute of Steel and Alloys

5-87623-126-6 Moscow 2005 Foundry alloys and melting

13. Materials cience Zharsky I.М., Ivanova N.P., Kyis D.V., Svidunovich

Vysheishaya shkola

978-985-06-2517-5

Minsk 2015 Metal technology and welding

442




Date of publicati

on


used


Com-ments

N.А.

14. Software control of technological systems in power engineering

Petrenko Y.N. and others

Vysheishaya shkola

978-985-06-2227-3

Minsk 2013 Computer-aided design and modeling of casting processes

15. Handarc welding Lypachev V.G. Vysheishaya shkola

978-985-06-2494-9


16. Arcandgas welding Gasparian V.H., Denisov L.S.

Vysheishaya shkola

978-985-06-2371-3


17. Technology of foundry production: sand casting

Tryhov А.P. Academia 5-7695-1757-3 Moscow 2005 Designing of equipment

18. Foundry equipment (1, 2 parts)

Matveenko I.V. MSIU 5-276-00360-2 (ч. 1)

Moscow 2003 Automatic lines and systems

19. Technologies of processes of mixtures preparation and production of sand casting molds

Kykyi D.М., Melnikov А.P., Rovin S.l. and others

BNTU 978-985-525-325-0

Minsk 2009 Automatic lines and systems

20. Foundry equipment: training

Matveenko I.V. MSIU 5-276-00897-3 (Ч. 1), 5-276-

Moscow 2006 Foundry equipment. Construction and

443




Date of publicati

on


used


Com-ments

manual. Part 1 00896-5 technological bases for machine production of cores

21 Foundry equipment: training manual. Part 2

Matveenko I.V. MSIU 978-5-2760-1.606-1 (Ч. 2), ISBN 978-5-2760-1607-8

Moscow 2009 Foundry equipment. Construction and technological bases for machine production of cores

22. Automation foundry production. Part. 1: Management of casting processes: a textbook

Novikov V.P. MSIU 5-276-00702-0 Moscow 2005 Automation of foundry production

23. Automation foundry production: a textbook

Kykyi D.М., Odinochko V.F.

Novoe znanie 978-985-475-302-7

Minsk 2008 Automation of foundry production

24. Economy of an organization

Volodko О.V., Grabar R.N., Zliyi Т.V.

Vysheishaya shkola

978-985-06-2560-1

Minsk 2015 Economy, organization and planning of production

25. Economy an organization (enterprise). Practicum

Volodko О.V., Grabar R.N., Zliyi Т.V.

Vysheishaya shkola

978-985-06-2396-6

Minsk 2015 Economy, organization and planning of production

444




Date of publicati

on


used


Com-ments

26. Economy, organization and planning of industrial production

Кarpey Т.V. Design PRO 985-452-097-8 Minsk 2004 Economy, organization and planning of production

27. Technical and economic planning of foundry production. Qualimetric approach

Perevoschikov Y.S., Zharina N.А. Myllina L.R.

LAPLAMBERT Academic Publishing

978-3-659-55511-4

Germany 2014 Economy, organization and planning of production

28. Economy, organization and planning of production at an enterprise

Shepelenko G. I. Feniks 6 978-5-241-00962-3

Rostov-on-Don

2010 Economy, organization and planning of production

29. Standardization and product quality control

Shvander V.А., Kypriakov V.P. and others; edited by professor V.А. Shvander

Unity - DANA 5-238-00112-6 Moscow 2000 Fundamentals of standardization and metrology. Industrial Training

30. General course of plumbing: a text book

Karpitskiy V.R. Novoe znanie 978-985-475-445-1

Minsk 2011 Industrial Training

445




Date of publicati

on


used


Com-ments

31. Procedures and equipment for production of Cold-box-am in cores

Kydin D.А., Kykyi D.М., Kyrakevich B.V., Melnikov А.P.

Novoe znanie 978-985-475-231-0

Minsk 2007 Professional practice

32. Engineering graphics

Kokoshko А.F., Matyh S.А.

RIPE 978-985-503-323-4

Minsk 2013 Fundamentals of engineering graphics

33. Technical mechanics

Vereina L. I. Academia 5-7695-3405-2 Moscow 2007 Fundamentals of technical mechanics

34. Technical mechanics

Tarasov V.N. TransLit 978-5-94976-455-8

Moscow 2010 Fundamentals of technical mechanics

35. Guide to solving problems in theoretical mechanics

Arkysha А.I. Vysheishaya shkola

978-5-06-006168-0


36. Theoretical mechanics. Theoretical mechanics and strength of materials

Arkysha А.I. LIBROKOM 978-5-397-04683-1


37 Technical mechanics

Vereina L. I.

Krfsnov M.M.

Academia 978-5-7695-8914-0


446




Date of publicati

on


used


Com-ments

Series : Secondary professional Obra - tion

38. Protection of labour, environment and rational nature management

Drizhd N.А. Foliant 9965-35-582-7 Astana 2009 Protection of labour and safety of life

39. Occupational safety Klujev U.V.. Foliant 9965-849-16-1 Astana 2010 Protection of labor, health and safety

40. Protection and rational use of natural resources: instructions book for organizing technological and profile education process

Abel E.V. Foliant 2 978-601-292-308-7

Astana 2011 Protection of labor, health and safety

41. Protection of labor and occupational safety.

Amanjolov G.K. Foliant 978-601-292-307-0

Astana 2011 Protection of labor, health and safety

42. Electro technics with the fundamentals of electronics

Sindeev Y.G. Feniks 978-5-222-17505-7

Rostov-on-Don

2010 Electro technics with the fundamentals of electronics

447




Date of publicati

on


used


Com-ments

43. Electro technics and electronics

Kononenko V. V.

Feniks 978-5-222-12830-5

Rostov-on-Don


44. Electro technics Butyrin P.А. Academmia 978-5-7695-3975-6

Moscow 2007 Electro technics with the fundamentals of electronics

45. Electro technics and electronics

Galperin М.V. Forum

Infra – М

978-5-8199-0176-2


46. General electro technics with the fundamentals of electronics

Danilov I.А. Vysheishaya shkola

978-5-06-005364-7


47. Electro technics. Theoretical fundamentals

Lotoreychuk Е. А.

Vysheishaya shkola

5-06-004450-6 Moscow 2005 Electro technics with the fundamentals of electronics

48. Electro technics NemtsovМ.V., SvetlakovaI.I.

Feniks 978-5-222-14696-5

Rostov-on-Don


49. General electro technics and fundamentals of industrial electronics

Rekyc G. G. Vysheishaya shkola

978-5-06-005441-5


448




Date of publicati

on


used


Com-ments

50. Electro technical reference book

Aliev I.I. IE «RadiоSoft» 978-5-9303-7213-7


51. Electro technical measurements

Pyctovaya О.А. Feniks 978-5-222-16097-8

Rostov-on-Don


52. Heat engineering: a textbook.

Erofeev, V.L.,Semenov P.D., Priahin А.S.

Academmia 978-5-94628-331-1

Moscow 2008 Heat engineering

53. Designing of foundry equipment

Isagulov A.Z.,

Kuzembaev S.B.,

Kanunnikova S.G.

KSTU 9965-606-83-8 Karaganda 2003 Designing of equipment

54. Molding and core foundry equipment

Matveenko I.V.,

Isagulov A.Z.

KSTU 9965-698-63-5 Karaganda 2004 Design and technological basis of the production of cores by means of manual molding Design and technological basis of machine core production

449

450

List of educational equipment

№ Item Technical specificationDisciplines to use the

equipment

The required number of items of equipment / per number of

students

Total required number

1

Laboratory runners (model

42110)

Length - 508mm

Width - 533mm

Height - 457mm

Weight - 100 kg

Power supply - 220V, 50-60Hz

Foundry theory and technology

1/20

2

Mixer of core sand mixtures

(Model 42111)

Length - 521mm

Width - 273 mm

Height - 324 mm

Weight - 50 kg



1/20

3

Molding sand sealant

(Model 42100)

Theory and Technology

foundry 1/20 2

Length - 191 mm

Width - 241 mm

Height - 559 mm

Weight - 22.7 kg


1/20

4

Electronic universal unit to determine the strength properties of

molding

mixtures (model 42104)

. Length - 457 mm

Width - 305 mm

Height - 305 mm

Weight - 30 kg


Compressed air pressure-5-6 atm.


1/20

451


equipment


students


5

Digital device for gas

permeability

(Model 42105)

Length - 260 mm

Width - 362 mm

Height - 521 mm

Weight - 21.8 kg


Compressed air pressure - 2.5-4.5 atm


1/20

6

Laboratory vibrating

screen (model 42106)

Length - 305 mm

Width - 362 mm

Height - 800 mm

Weight - 39.1 kg



1/20

7

Analyzer clay (using

methylene blue)

(Model 42108)

Length -25mm

Width - 305 mm

Height - 749 mm

Weight - 20.9 kg


1/40

8 Sand blaster (model 42109)

Length - 432 mm

Width - 406 mm

Height - 584 mm

Weight - 47.3 kg

Foundry theory and technology, foundry shop

equipment

1/40

452


equipment


students



9Calibration Kit (Model 42113)

Length - 445 mm

Width - 311 mm

Height - 483 mm

Weight - 50 kg


1/20

10Digital Scales (model 42118)

Length - 345 mm

Width - 231 mm

Height - 89 mm

Weight - 4 kg

Foundry theory and technology, foundry shop equipment, foundry alloys

and melting

1/40

11

The unit for an accelerated

mixture cleaning

(model 42119)

Length - 305 mm

Width - 216 mm

Height - 216 mm

Weight - 5.5 kg



1/40

12 Muffle furnace (Model 42126)

Length - 305 mm

Width - 216 mm

Height - 216 mm

Weight - 5.5 kg


Foundry theory and technology, foundry alloys

and melting

1/20

453


equipment


students


13Drying oven

(Model 42128)

Length - 584 mm

Width - 813 mm

Height - 489 mm

Weight - 63.6 kg



and melting1/20

14The moisture

analyzer (Model 42130)

Length - 229 mm

Width - 356 mm

Height - 152 mm

Weight - 4.5 kg



and melting1/40

15AFS clay

tester (model 42131)

Length - 584 mm

Width - 343 mm

Height - 279 mm

Weight - 11.4 kg


1/40

16

Electronic Mold

Hardness Tester (Model

42142)

Length - 102 mm

Width - 64 mm

Height - 32 mm

Weight - 0.17 kg


1/20

454


equipment


students


17

Laboratory induction melting furnace

Supply voltage - 220V,

The capacity of the crucible - 150 cm3

Power - 4 kW

Foundry theory and technology, foundry shop equipment, foundry alloys

and melting

1/40

18 Crucibles setCrucible - 150, 250, 350

cm3


and melting1/10

19

Casting test samples set

Spiral of Kerry

U-shaped sample,

Bar-shaped sample,

Ball sample

Foundry alloys and melting 1/40

20Personal computer

CPU Intel Core i3 4025U 1900 MHz, RAM DDR3 32GB, HDD 1000 GB,

Intel HD Graphics 4400, power supply unit 45 W

Foundry theory and technology, foundry shop equipment, foundry alloys and melting, CAD, tooling design, foundry automation

and etc.

1/1

455