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Risk Assessment of Defect Occurrences in Engine Piston Castings by FMEA Method

Piątkowski J., Kamiński P.

Archives of Foundry Engineering

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2017

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Vol. 17, iss. 3

107--110

EN

The FMEA (Failure Mode and Effects Analysis) method consists in analysis of failure modes and evaluation of their effects based on determination of cause-effect relationships for formation of possible product or process defects. Identified irregularities which occur during the production process of piston castings for internal combustion engines were ordered according to their failure rates, and using Pareto-Lorenz analysis, their per cent and cumulated shares were determined. The assessments of risk of defects occurrence and their causes were carried out in ten-point scale of integers, while taking three following criteria into account: significance of effects of the defect occurrence (LPZ), defect occurrence probability (LPW) and detectability of the defect found (LPO). A product of these quantities constituted the risk score index connected with a failure occurrence (a so-called “priority number,” LPR). Based on the observations of the piston casting process and on the knowledge of production supervisors, a set of corrective actions was developed and the FMEA was carried out again. It was shown that the proposed improvements reduce the risk of occurrence of process failures significantly, translating into a decrease in defects and irregularities during the production of piston castings for internal combustion engines.

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The Effect of the Number of Eutectic Grains on Coating Growth During Hot Dip Galvanising of Ductile Iron Castings

Kopyciński D., Guzik E., Szczęsny A.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 1

67--70

EN

Studies were conducted on a zinc coating produced on the surface of ductile iron grade EN-GJS-500-7 to determine the eutectic grain effect. For this purpose, castings with a wall thickness of 5 to 30 mm were made and the resulting structure was examined. To obtain a homogeneous metal matrix, samples were subjected to a ferritising annealing treatment. To enlarge the reaction surface, the top layer was removed from casting by machining. Then hot dip galvanising treatment was performed at 450°C to capture the kinetics of growth of the zinc coating (in the period from 60 to 600 seconds). Analysing the test results it was found that within the same time of hot dip galvanising, the differences in the resulting zinc coating thickness on samples taken from castings with different wall cross-sections were small but could, particularly for shorter times of treatment, reduce the continuity of the alloyed layer of the zinc coating.

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Influence of Wax Pattern Surface Quality on Prime Coat of Ceramic Mold

Bałkowiec A., Wawulska P., Matysiak H., Rabajczyk A., Smektała P., Zdunek J., Kurzydłowski K.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 1 spec.

67--72

EN

The authors have made an attempt to enrich the knowledge about the influence of wax pattern washing process and its influence on the quality of the shell prime coat. Two types of wax were investigated: A7Fr/60 and KC2690. A7Fr60 is used for pattern fabrication, while KC2690 is typical sprue wax. The goal of work was to establish wax solubility accuracy in Trisol 60 Plus and Houghto Clean 530 versus time and influence of dipping time to wax samples surface quality. Additionally, after exposition of wax samples, their surface morphology was characterized with the use of laser profilometry and surface roughness measurement. The quality of formed prime coat was established by X-ray tomography. The measurement of wetting angle of the wax by binder was conducted. The results have shown that the main factor which influences the quality of the prime coat is surface wettability rather than wax surface roughness.

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Baza danych technologii w odlewniach żeliwa i staliwa z wykorzystaniem systemu SimulationDB

Malinowski P., Suchy J. S.

Archives of Foundry Engineering

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2013

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Vol. 13, iss. 3 spec.

117--122

PL

Dotychczasowy sposób przechowywania danych technologicznych w postaci zdjęć, animacji, wykresów, zestawów parametrów, wyników symulacji, danych produkcyjnych umieszczonych w określonej strukturze katalogów uniemożliwia przetwarzanie i powtórne wykorzystanie tych informacji. Rosnąca w szybkim tempie liczba wykonywanych symulacji w branży odlewniczej powoduje generowanie bardzo dużej ilości cyfrowych danych liczonych w terabajtach, które należy odpowiednio przetworzyć i zinterpretować – natychmiast reagując na powstałe nieprawidłowości podczas procesu zalewania i/lub krzepnięcia odlewu. Mogą to jedynie wykonać wysoko wyspecjalizowani inżynierowie-eksperci. Ich wiedza, doświadczenie praktyczne i umiejętność posługiwania się nowatorskimi narzędziami inżynierskimi, wspomagającymi różne etapy przygotowania produkcji decyduje o szybkości przygotowania technologii przy zachowaniu parametrów jakościowych i wytrzymałościowych. Umiejętnie spisana wiedza praktyczna, opis postępowania technologa, wyniki symulacji oraz cały proces produkcji odlewniczej zawarte w technologicznej bazie wiedzy SimulationDB tworzą niezbędne narzędzie nowoczesnego technologa. Wykorzystanie wiedzy technologicznej zawartej w systemie SimulationDB umożliwia szybsze opracowanie technologii, skuteczne rozwiązywanie problemów technologicznych, szkolenie kadry specjalistów, co w efekcie tworzy dodatkową wartość dodaną.

EN

The method used so far for storing technological data – i.e. images, animations, charts, sets of parameters, simulation results and production data contained in a defined directory structure makes processing and re-using this information basically impossible. The number of simulations carried out in the casting industry is growing very rapidly. This generates terabytes of digital data that need to be processed and interpreted properly, as irregularities arising during the process of pouring and/or solidification of the casting have to be addressed immediately. Only highly-specialized engineers/experts can perform these tasks. Their knowledge, experience and ability to use innovative engineering tools, that support various stages of the production preparation process, are crucial factors determining how fast a technology can be developed in compliance with the given quality and strength parameters. An appropriate record of practical knowledge, technologists’ guidance, simulation results, as well as the entire process of casting production, that are included in the technological knowledge base SimulationDB, provide for an essential tool of a modern technologist. The use of technological knowledge provided by the SimulationDB system allows for faster development of technologies, effective problem-solving in technological processes, and training of specialists. As a result, this all creates additional added value.