REDUCING AMINE GAS CONSUMPTION IN FOUNDRY CORE PRODUCTION PROCESS BY OPTIMIZATION OF MACHINE PARAMETERS

Yıl 2025, Cilt: 13 Sayı: 1, 306 - 324, 20.03.2025

Onur Şahin , Müge Ensari Özay , Rüştü Uçan , Emine Can

https://doi.org/10.21923/jesd.1561319

Öz

One of the most important hazards in the foundry core production process is dimethylethylamine gas. DMEA (Dimethylethylamine) is an extremely volatile compound used in core hardening and has been reported to cause cancer and eye damage. It also risks process safety. In order to prevent this, the amount of DMEA injected into the core should be reduced without negatively affecting the core quality. The way to do this is to adjust the machine parameters used during core production to optimum values and to obtain the desired core hardness with the minimum amount of DMEA. In this article, it is aimed to obtain the optimization of the parameters affecting the core hardness in order to reduce the amount of DMEA by experimental research using the factorial design of experiments. For this purpose, 32 core production recipes were created with two levels of 10 core production parameters in the core production department of a foundry. The indentation hardness of the produced cores was measured and recorded. The results were analyzed with the Minitab 22 package program. The regression equation of the hardness output depending on the factors was obtained. One of the most important findings was that the amount of DMEA used could be reduced by increasing the gas temperature and reducing the gassing time without adversely affecting the desired core hardness. In addition, in terms of operational efficiency, reducing the gassing time will increase the number of cores produced per unit time. Less use of amine gas will also have positive effects on the quality of the casting part.

Anahtar Kelimeler

Casting, Core, Dimethylethylamine, Machine parameters, Fractional factorial test.

Etik Beyan

No conflict of interest was declared by the authors.

Teşekkür

We would like to thank Döktaş Dökümcülük Orhangazi facilities for their support in conducting the experiments for this study.

DÖKÜMHANE MAÇA ÜRETİM PROSESİNDE MAKİNE PARAMETRELERİ OPTİMİZASYONU İLE AMİN GAZI TÜKETİMİNİN AZALTILMASI

Öz

Dökümhane maça üretim sürecinde en önemli tehlikelerden biri dimetiletilamin gazıdır. DMEA (Dimetiletilamin) maça sertleştirmede kullanılan aşırı uçucu bir bileşik olup kansere ve göz hasarına sebep olduğu bildirilmiştir. Ayrıca proses güvenliğini riske sokmaktadır. Bunun önüne geçmek için DMEA miktarının maça kalitesine negatif etki yapmadan maçaya enjekte edilen miktarının azaltılması gerekir. Bunu yapabilmenin yolu da maça üretimi sırasında kullanılan makine parametrelerinin optimum değerlere ayarlanması ile minimum miktarda DMEA ile istenen maça sertliğinin elde edilmesidir. Bu makalede faktöriyel deney tasarımı metodu kullanılarak deneysel araştırma ile DMEA miktarının azaltılması için maça sertliğine etki eden parametrelerin optimizasyonu elde edilmesi amaçlanmıştır. Bu amaçla bir dökümhanenin maça üretim bölümünde 10 adet maça üretim parametresinin iki seviyesi ile 32 adet maça üretim reçetesi oluşturulmuştur. Üretilen maçaların batma sertlikleri ölçülmüş ve kayıt edilmiştir. Ortaya çıkan sonuçların Minitab 22 paket program ile analizleri yapılmıştır. Sertlik çıktısının faktörlere bağlı regresyon eşitliği elde edilmiştir. En önemli bulgulardan biri istenen maça sertliğini olumsuz etkilemeden gaz sıcaklığının artırılması ve gazlama süresinin düşürülmesi ile kullanılan DMEA miktarının azaltılabileceği olmuştur. Ayrıca, işletme verimliliği açısından da gazlama süresinin düşürülmesi birim zamanda üretilen maça sayısını artıracaktır. Amin gazının daha az kullanılması ile de döküm parça kalitesine olumlu yansımalar olacaktır.

Anahtar Kelimeler

Döküm, Maça, Dimetiletilamin, Makine parametreleri, Kesirli faktöryel deney

Etik Beyan

Yazarlar tarafından herhangi bir çıkar çatışması beyan edilmemiştir.

Teşekkür

Bu çalışma için deneylerin yapılmasında destek olan Döktaş Dökümcülük A.Ş. Orhangazi tesislerine teşekkür ederiz.

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