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1
Content available remote Robotization of the process of removal of the gating system in an enterprise from the automotive industry
Bucior Magdalena, Kluz Rafał, Kubit Andrzej
Technologia i Automatyzacja Montażu
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2020
|
nr 1
10--15
EN
Cleaning and removal of components of the gating system, and finishing of castings are the most labor-consuming and damaging to health foundry processes. This paper presents the results of an analysis of labor consumption of the process of removal of gating systems of aluminium castings, which were carried out in a conventional manner using a band saw and a boring machine, and using an industrial robot. In the final part of this paper the analysis of occupational hazard of work-stands is presented. It has been shown that the use of robotization leads to an increase both the productivity of the process and work safety. The use of an industrial robot allows to reduce the labor consumption of the process of removal of gating systems by 29,5% in relation to the non-robotized stand. Furthermore, on the robotized stand almost all the time needed for the process of removal of the gating system is connected with the machining. It represents 98.7% of the production cycle. In the case of non-robotized stand, the machining takes 79% of the total time required for treatment of one piece of the casting.
PL
Oczyszczanie, usuwanie elementów układu wlewowego oraz wykańczanie odlewów należą do najbardziej pracochłonnych, szkodliwych dla zdrowia oraz niebezpiecznych procesów odlewniczych. W pracy przedstawiono analizę pracochłonności procesu usuwania układów wlewowych odlewów aluminiowych, realizowanego w sposób konwencjonalny z zastosowaniem pilarki taśmowej i wytaczarki oraz z zastosowaniem robota przemysłowego. W końcowej części pracy dokonano analizy ryzyka zawodowego stanowisk pracy i wykazano, że wprowadzenie robotyzacji procesu prowadzi do zwiększenia jego wydajności oraz bezpieczeństwa pracy. Zastosowanie robota przemysłowego umożliwia zmniejszenie pracochłonności procesu usuwania układów wlewowych o 29,5% w stosunku do stanowiska niezrobotyzowanego. Na stanowisku zrobotyzowanym, niemalże cały czas potrzebny na realizację procesu usuwania układu wlewowego jest poświęcony na obróbkę właściwą. Stanowi ona 91% cyklu produkcyjnego. W przypadku stanowiska niezrobotyzowanego, obróbka właściwa zajmuje 80% całego czasu potrzebnego na obrobienie jednej sztuki odlewu.
2
Content available The Use of Abrasive Waterjet Cutting to Remove Flash from Castings
Bańkowski D., Spadło S.
Archives of Foundry Engineering
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2019
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iss. 3
94--98
EN
This article proposes to use abrasive waterjet cutting (AWJ) for deflashing, deburring and similar finishing operations in casting. The basic requirements concerning the dimensional accuracy and surface texture of cast components are not met if visible surface flaws are detected. The experiments focused on the removal of external flash from elements made of EN-GJL-150 cast iron. The method employed for finishing was abrasive waterjet cutting. The tests were carried out using an APW 2010BB waterjet cutting machine. The form profiles before and after flash removal were determined with a Taylor Hobson PGI 1200 contact profiler. A Nikon AZ100 optical microscope was applied to observe and measure the changes in the flash height and width. The casting surface after finishing was smooth, without characteristic sharp, rough edges that occur in the cutting of objects with a considerable thickness. It should be emphasized that this method does not replace precise cutting operations. Yet, it can be successfully used to finish castings for which lower surface quality is required. An undoubted advantage of waterjet cutting is no effect of high temperature as is the case with plasma, laser or conventional cutting. This process is also easy to automate; one tool is needed to perform different finishing operations in order to obtain the desired dimensions, both internal and external.
3
Content available Modelling and Simulation Method for Production Process Automation in Steel Casting Foundry
Kampa A., Gołda G.
Archives of Foundry Engineering
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2018
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Vol. 18, iss. 1
47--52
EN
The problem of production flow in steel casting foundry is analysed in this paper. Because of increased demand and market competition, a reorganisation of the foundry process is required, including the elimination of manual labour and the implementation of automation and robotisation of certain processes. The problem is how to determine the real difference in work efficiency between human workers and robots. We show an analysis of the production efficiency of steel casting foundry operated by either human operators or industrial robots. This is a problem from the field of Operations Research for which the Discrete Event Simulation (DES) method is used. Three models are developed, including the foundry before and after automation when taking into consideration parameters of the availability of machines, operators and robots. We apply the OEE (Overall Equipment Effectiveness) indicator to present how the availability, performance and quality parameters influence the foundry’s productivity. In addition, stability of the simulation model was analysed. This approach allows for a better representation of real production processes and the obtained results can be used for further economic analysis.
4
Content available Influence of the Home Scrap Content on the Service Life of Equipment Used in High Pressure Die Casting of AZ91 Alloy
Konopka Z., Łągiewka M., Zyska A.
Archives of Foundry Engineering
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2018
|
Vol. 18, iss. 2
173--176
EN
The results of estimation of home scrap addition in charge influence on durability and wear of casting instrumentation life in the high-pressure casting technology using the hot chamber machine of alloy of AZ91 are presented. The wear of the following elements of the casting instrumentation so-called "casting set" as: syphon, plunger, sliding-rings, nozzle and injection moulding nozzle was estimated. A wear was estimated quantitative by registering the number of mould injections for different charges to the moment of element damage supervision. A damage had to be at such level that liquidated an element from further exploitation and necessary was an exchange on new or regeneration. In a final result allowed it the detailed determination of durability of the applied rigging elements in dependence on the type of the applied type of melt. It is noticed, that together with the increase of home-scrap participation in the charge wear of pressure machine instrumentation elements increases.
5
Content available Increasing the Capability of the Process of Placing Inserts in Foundry Moulds
Jaworski J., Kluz R., Trzepieciński T.
Archives of Foundry Engineering
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2018
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Vol. 18, iss. 2
187--190
EN
This article discusses the issue of the preparation of the foundry moulds with the use of an industrial robot. The methodology is presented for the determination of the process capacity index for placing inserts with flat and cylindrical faces. On the basis of the relationships developed, the process capability indices were determined at various points in the workspace, which are characterised by different values of the repeatability positioning error. It was shown that the value of the process capacity index can be increased by the selection of a suitable location for the process of placing the inserts in the workspace. It should also be noted that the value of the process's capability index depends on the selection of the place in the robot workspace where the process is carried out. Implementation of the joining process at an analysed point in the robot workspace leads to an increase of the process capability index MCp for inserts with flat faces up to 1.1 (+4.5%) and for inserts with cylindrical faces up to 1.3. This results in an increase of 13% to a level corresponding to the global standard for process reliability (MCp = 1.33).
6
Content available The Influence of Home Scrap on Porosity of MgAl9Zn1 Alloy Pressure Castings
Konopka Z., Chojnacki A., Łągiewka M., Zyska A.
Archives of Foundry Engineering
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2017
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Vol. 17, iss. 1
99--102
EN
The work presents the results of examinations concerning the influence of various amounts of home scrap additions on the porosity of castings made of MgAl9Zn1 alloy. The fraction of home scrap in the metal charge ranged from 0 to 100%. Castings were pressure cast by means of the hot-chamber pressure die casting machine under the industrial conditions in one of the domestic foundries. Additionally, for the purpose of comparison, the porosity of specimens cut out directly of the MgAl9Zn1 ingot alloy was also determined. The examinations consisted in the qualitative assessment of porosity by means of the optical microscopy and its quantitative determination by the method of weighting specimens in air and in water. It was found during the examination that the porosity of castings decreases with an increase in the home scrap fraction in the metal charge. The qualitative examinations confirmed the beneficial influence of the increased home scrap fraction on the porosity of castings. It was concluded that the reusing of home scrap in a foundry can be a good way of reduction of costs related to the production of pressure castings.
7
Content available The Influence of Home Scrap on Mechanical Properties of MgAl9Zn1 Alloy Castings
Konopka Z., Chojnacki A. C., Łągiewka M., Zyska A.
Archives of Foundry Engineering
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2017
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Vol. 17, iss. 2
39--42
EN
The work presents the results of examinations concerning the influence of various amounts of home scrap additions on the properties of castings made of MgAl9Zn1 alloy. The fraction of home scrap in the metal charge ranged from 0 to 100%. Castings were pressure cast by means of the hot-chamber pressure die casting machine under the industrial conditions in one of the domestic foundries. The examinations consisted in the determination of the following properties: tensile strength Rm, yield strength Rp0.2, and the unit elongation A5, all being measured during the static tensile test. Also the hardness measurements were taken by the Brinell method. It was found that the mechanical properties (mainly the strength properties) are being improved up to the home scrap fraction of 50%. Their values were increased by about 30% over this range. Further rise in the home scrap content, however, brought a definite decrease in these properties. The unit elongation A5 exhibited continual decrease with an increase in the home scrap fraction in the metal charge. A large growth of hardness was noticed for the home scrap fraction increasing up to the value of 50%. Further increasing the home scrap percentage, however, did not result in a significant rise of the hardness value any more.
8
Content available Improving Quality and Occupational Safety on Automated Casting Lines
Kukla S.
Archives of Foundry Engineering
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2017
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Vol. 17, iss. 3
69--72
EN
The paper presents a practical example of improving quality and occupational safety on automated casting lines. Working conditions on the line of box moulding with horizontal mould split were analysed due to low degree of automation at the stage of cores or filters installation as well as spheroidizing mortar dosing. A simulation analysis was carried out, which was related to the grounds of introducing an automatic mortar dispenser to the mould. To carry out the research, a simulation model of a line in universal Arena software for modelling and simulation of manufacturing systems by Rockwell Software Inc. was created. A simulation experiment was carried out on a model in order to determine basic parameters of the working system. Organization and working conditions in other sections of the line were also analysed, paying particular attention to quality, ergonomics and occupational safety. Ergonomics analysis was carried out on manual cores installation workplace and filters installation workplace, and changes to these workplaces were suggested in order to eliminate actions being unnecessary and onerous for employees.
9
Content available Research on Accuracy of Automatic System for Casting Measuring
Jaworski J., Kluz R, Trzepieciński T.
Archives of Foundry Engineering
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2016
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Vol. 16, iss. 3
49--54
EN
Ensuring the required quality of castings is an important part of the production process. The quality control should be carried out in a fast and accurate way. These requirements can be met by the use of an optical measuring system installed on the arm of an industrial robot. In the article a methodology for assessing the quality of robotic measurement system to control certain feature of the casting, based on the analysis of repeatability and reproducibility is presented. It was shown that industrial robots equipped with optical measuring systems have the accuracy allowing their use in the process of dimensional control of castings manufactured by lost-wax process, permanent-mould casting, and pressure die-casting.
10
Content available Quality and Safety Assurance of Iron Casts and Manufacturing Processes
Kukla S.
Archives of Foundry Engineering
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2016
|
Vol. 16, iss. 2
17--20
EN
The scope of this work focuses on the aspects of quality and safety assurance of the iron cast manufacturing processes. Special attention was given to the processes of quality control and after-machining of iron casts manufactured on automatic foundry lines. Due to low level of automation and huge work intensity at this stage of the process, a model area was established which underwent reorganization in accordance with the assumptions of the World Class Manufacturing (WCM). An analysis of work intensity was carried out and the costs were divided in order to identify operations with no value added, particularly at individual manufacturing departments. Also an analysis of ergonomics at work stations was carried out to eliminate activities that are uncomfortable and dangerous to the workers' health. Several solutions were proposed in terms of rationalization of work organization at iron cast after-machining work stations. The proposed solutions were assessed with the use of multi-criteria assessment tools and then the best variant was selected based on the assumed optimization criteria. The summary of the obtained results reflects benefits from implementation of the proposed solutions.
11
Content available Modelling and Optimization of Organization of Workplaces in a Foundry
Kukla S.
Archives of Foundry Engineering
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2016
|
Vol. 16, iss. 3
55--58
EN
The paper presents a practical example of improvement of foundry production systems in terms of post-finishing of nodular iron castings produced in the conditions of bulk production for automotive industry. The attention was paid to high labour-intensive efforts, which are difficult to be subjected to mechanization and automation. The times of actions related to grinding processing of castings in three grinding positions connected with a belt conveyor were estimated with the use of a time study method. A bottleneck as well as limiting factors were specified in a system. A number of improvements were proposed, aimed at improving work organization on the castings post-finishing line. An analysis of work ergonomics at the workplace was made in order to eliminate unnecessary and onerous for the employee actions. A model of production system using the Arena software, on which a simulation experiment was conducted, was drawn up in order to visualize the analysed phenomena. The effects of the project were shown on graphs comparing times, costs, work ergonomics and overall efficiency of production equipment indicator.
12
Content available The Use of Formal Knowledge Representation in Operating on Resources Concerning Cast Iron Processing
Kluska-Nawarecka S., Wilk-Kołodziejczyk D., Rojek G., Regulski K., Polek G.
Archives of Foundry Engineering
|
2015
|
Vol. 15, iss. 2
39--42
EN
The problem of materials selection in terms of their mechanical properties during the design of new products is a key issue of design. The complexity of this process is mainly due to a multitude of variants in the previously produced materials and the possibility of their further processing improving the properties. In everyday practice, the problem is solved basing on expert or designer knowledge. The paper is the proposition of a solution using computer-aided analysis of material experimental data, which may be acquired from external data sources. In both cases, taking into account the rapid growth of data, additional tools become increasingly important, mainly those which offer support for adding, viewing, and simple comparison of different experiments. In this paper, the use of formal knowledge representation in the form of an ontology is proposed as a bridge between physical repositories of data in the form of files and user queries, which are usually formulated in natural language. The number and the sophisticated internal structure of attributes or parameters that could be the criteria of the search for the user are an important issue in the traditional data search tools. Ontology, as a formal representation of knowledge, enables taking into account the known relationships between concepts in the field of cast iron, materials used and processing techniques. This allows the user to receive support by searching the results of experiments that relate to a specific material or processing treatment. Automatic presentation of the results which relate to similar materials or similar processing treatments is also possible, which should make the conducted analysis of the selection of materials or processing treatments more comprehensive by including a wider range of possible solutions.
13
Content available The Production of Plaster Molds with Patternless Process Technology
Pastirčák R., Sládek A., Kucharčíková E.
Archives of Foundry Engineering
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2015
|
Vol. 15, iss. 2
91--94
EN
The work deals with technology Patternless process that combines 3 manufacturing process mold by using rapid prototyping technology, conventional sand formation and 3D milling. It's unconventional technology that has been developed to produce large-sized and heavy duty castings weighing up to several tons. It is used mainly in prototype and small batch production, because eliminating production of models. The work deals with the production of blocks for making molds of gypsum and gypsum drying process technology Thermomold. Into blocks, where were made cavities by milling were casted test castings from AlSi10MgMn alloy by gravity casting. At machining of the mold cavity was varied feed rate of tool of cemented carbide. Evaluated was the surface roughness of test castings, that was to 5 micrometers with feed from 900 to 1300 mm/min. The dimensional accuracy of castings was high at feed rate of 1000 and 1500 mm/min did not exceed 0.025 mm.
14
Content available Improving the Organization of Iron Casts Finishing Processes
Kukla S.
Archives of Foundry Engineering
|
2015
|
Vol. 15, iss. 2 spec.
55--58
EN
The paper presents issues of production processes improvement in foundries in terms of finishing treatment of iron casts on grinding workstations. Basing on the conducted analysis of work ergonomics on the grinding line and the observation of work at workstations, a range of improvements related to organizing grinding treatment processes was proposed. In order to visualize the production system functioning and estimate its efficiency, a simulation model of a grinding line has been created, on which a simulation experiment was carried out. Due to many factors influencing the effectiveness of processes, it was suggested to use multi-criteria evaluation tools to choose the most rational solution. Three criteria have been assumed, according to which particular improvement variants were evaluated. Also, criteria weights have been set according to the Saaty’s method, and particular solution variants have been assessed separately with respect to each criterion. On the basis of the presented course of action, the best solution has been selected from among the analyzed options.
15
Content available Multi-Criterion Assessment of Different Variants of Casts Manufacturing Processes
Kukla S.
Archives of Foundry Engineering
|
2014
|
Vol. 14, iss. 3
47--50
EN
The paper presents the issue of production processes improvement in foundries in the area of finishing treatment of iron casts manufactured on automated foundry lines with vertical or horizontal mould division. Due to numerous factors which influence the efficiency of the processes, multi-criterion assessment tools were proposed in order to select the optimal solution for the assumed criteria. After determining the criteria weight using the Saaty method, a simulation experiment was designed and carried out which presents possible scenarios of casts finishing treatment operations. Basing on experiment reports from a computer model, particular solutions were evaluated using the Yager’s method. The evaluation of the experiment results was performed by experts who assessed different options according to each of the criteria adopted. After the establishment of the total standardized ratings by averaging the scores given by individual experts, the final decision was generated. Using the presented method, the best solution was chosen from among the analyzed scenarios.
16
Content available Aspects of Quality Assurance in Mechanization of Core Making Process
Asłanowicz M., Fedoryszyn A., Fulko T., Ościłowski A.
Archives of Foundry Engineering
|
2014
|
Vol. 14, iss. 1 spec.
43--46
EN
The article presents conclusions drawn from analysis and research conducted in domestic foundries concerning currently used core shop equipment as well as determination of their needs within this area. Works within mechanization of core making process, conducted together by Ferro-Masz company, Łódź and Faculty of Foundry Engineering of AGH, Kraków, included analysis of available technologies, applied materials and requirements for mechanization of core making process with the use of blowing methods. Commercial offers from manufacturers of core making systems has been discussed together with presentation of own solution of universal core shooting/blowing machine, ensuring production of high-quality cores.
17
Content available Application of Neural Networks into Prediction of Qualitative Capability of the Preparation Process of Casting Moulds
Jaworski J., Kluz R., Trzepieciński T.
Archives of Foundry Engineering
|
2014
|
Vol. 14, iss. 1 spec.
9--12
EN
In the article the problem of assurance of qualitative capability of the preparation process of casting moulds using artificial neural net-works is presented. Using STATISTICA Neural Networks a set of the best networks is found. Obtained results of neural modeling were compared with the results of experimental investigations and classical mathematical modeling. The appropriate architecture of the neural network is chosen that predicts the quality capability of the preparation process of casting moulds with the high precision.
18
Content available Virtual factory as a method of foundry design and production management
Stawowy A., Wrona R., Brzeziński M., Ziółkowski E.
Archives of Foundry Engineering
|
2013
|
Vol. 13, iss. 1
113--118
EN
The paper outlines the methodology of virtual design of a foundry plant as a system. The most important stage in the procedure involves the development of a model defined as a set of data about the system. Model development involves two stages: defining the model’s architecture and specifying the model data in the form of parameters and input-output relationships. The structure is understood as configuration of machines and transport units, representing the sub-systems and system components. As the main purpose of the simulation procedure is to find the characteristics of the system’s behaviour, the merits of the iterative method involving analysis, synthesis and evaluation of results are fully explored.
19
Content available Programowanie sterowników PLC metodą nauczania
Więcławek R.
Archives of Foundry Engineering
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2013
|
Vol. 13, iss. 1 spec.
189--192
PL
Do automatyzacji procesów odlewniczych powszechnie stosowane są programowalne sterowniki logiczne PLC. Języki oraz znane metody programowania sterowników PLC sprawiają duże trudności przy implementacji rozwiązań dotyczących sterowania procedurami sekwencyjnymi. Dlatego podjęto prace nad opracowaniem metody, która umożliwiłaby łatwe programowanie procedur sekwencyjnych przez użytkowników nie będących automatykami. Efektem tych prac jest aplikacja opracowana dla sterowników Simatic S7-300, która umożliwia ich programowanie metodą stosowaną w robotyce – programowaniem poprzez nauczanie. Przeprowadzone badania wykazały możliwość stosowania tej metody do programowania dowolnych procedur sekwencyjnych o dowolnej liczbie kroków. Jedynym ograniczeniem jest rozmiar pamięci operacyjnej sterownika. Aplikację można też implementować w dowolnym sterowniku PLC, którego języki programowania są zgodne z normą IEC61131. Dalsze badania będą dotyczyły opracowania aplikacji umożliwiającej programowanie procedur sekwencyjnych, w których przejście do następnego kroku jest uzależnione od upływu zadanego czasu.
EN
In automation of foundry processes, commonly used are programmable logic controllers (PLC). Languages and known methods of programming the PLC controllers cause big difficulties at implementing solutions concerning control of sequential procedures. This is why undertaken were the works on developing a method that would facilitate programming sequential procedures by the users not being automatic specialists. These works resulted in an application developed for the controllers Simatic S7-300 written in the STL language that makes possible their programming with the method commonly used in robotics, i.e. by teaching-in. The carried-out examinations showed a possibility to use this method for programming any sequential procedures with any number of steps. The only restriction is size of operational memory of the controller. The application can be also implemented in any PLC controller whose programming language is compliant with the standard IEC 61131. Further research will be aimed at developing an application that would permit programming sequential procedures where transition to the following step is dependent on expiry of the preset time.
20
Content available Characteristic of core manufacturing process with use of sand, bonded by ecological friendly nonorganic binders
Fedoryszyn A., Dańko J., Dańko R., Asłanowicz M., Fulko T., Ościłowski A.
Archives of Foundry Engineering
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2013
|
Vol. 13, iss. 3
19--24
EN
Mechanization of the process of core making with the use of inorganic and organic binders is based, almost solely, on core blowing machines. Presently the core blowing machines are equipped with tools and devices that allow for application of different technologies of core making. Cold-box, hot-box and warm-air technologies require that core blowing machines shall be additionally equipped with either core-box pre-heating system or gas purging and neutralization system, or hot air purging systems. Considering the possibility of using varied, the most advantageous technologies of core making, the production of universal core blowing machines equipped with replaceable devices has been undertaken in Poland. The universal core blowing systems allow for mechanization of core making process also with the use of sand, bonded by modern, eco-friendly binder systems. The paper presents selected results-based evaluation of core blowing process showing the scope of conducted design and implementation works.
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