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1
Content available Experimental Verification of the Cast Iron Solidification Model
Mendakiewicz Jerzy
Archives of Foundry Engineering
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2022
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Vol. 22, iss. 3
91--94
EN
The article concerns the experimental verification of the numerical model simulating the solidification and cooling processes proceeding in the domain of cast iron casting. The approximate course of the function describing the evolution of latent heat and the value of substitute specific heat resulting from its course were obtained using the thermal and derivative analysis (TDA) method The TDA was also used to measure the cooling curves at the distinguished points of the casting. The results obtained in this way were compared with the calculated cooling curves at the same points. At the stage of numerical computations, the explicit scheme of the finite difference method was applied. The agreement between the measured and calculated cooling curves is fully satisfactory.
2
Content available Methodology for Diagnosing the Causes of Die-Casting Defects, Based on Advanced Big Data Modelling
Okuniewska A., Perzyk M. A., Kozłowski J.
Archives of Foundry Engineering
|
2021
|
Vol. 21, iss. 4
103--109
EN
The purpose of this paper was to develop a methodology for diagnosing the causes of die-casting defects based on advanced modelling, to correctly diagnose and identify process parameters that have a significant impact on product defect generation, optimize the process parameters and rise the products’ quality, thereby improving the manufacturing process efficiency. The industrial data used for modelling came from foundry being a leading manufacturer of the high-pressure die-casting production process of aluminum cylinder blocks for the world's leading automotive brands. The paper presents some aspects related to data analytics in the era of Industry 4.0. and Smart Factory concepts. The methodology includes computation tools for advanced data analysis and modelling, such as ANOVA (analysis of variance), ANN (artificial neural networks) both applied on the Statistica platform, then gradient and evolutionary optimization methods applied in MS Excel program’s Solver add-in. The main features of the presented methodology are explained and presented in tables and illustrated with appropriate graphs. All opportunities and risks of implementing data-driven modelling systems in high-pressure die-casting processes have been considered.
3
Content available Introducing Advanced Data Analytics in Perspective of Industry 4.0 in a Die Casting Foundry
Perzyk M., Dybowski B., Kozłowski J.
Archives of Foundry Engineering
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2019
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iss. 1
53--57
EN
The paper presents some aspects of a development project related to Industry 4.0 that was executed at Nemak, a leading manufacturer of the aluminium castings for the automotive industry, in its high pressure die casting foundry in Poland. The developed data analytics system aims at predicting the casting quality basing on the production data. The objective is to use these data for optimizing process parameters to raise the products’ quality as well as to improve the productivity. Characterization of the production data including the recorded process parameters and the role of mechanical properties of the castings as the process outputs is presented. The system incorporates advanced data analytics and computation tools based on the analysis of variance (ANOVA) and applying an MS Excel platform. It enables the foundry engineers and operators finding the most efficient process variables to ensure high mechanical properties of the aluminium engine block castings. The main features of the system are explained and illustrated by appropriate graphs. Chances and threats connected with applications of the data-driven modelling in die casting are discussed.
4
Content available Integrated Analytical and Measurement System for the Evaluation of the Properties of Cast Metals and Alloys
Biernat S., Bydałek A. W.
Archives of Foundry Engineering
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2019
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iss. 1
13--18
EN
The article presents an integrated analytical and measurement system for evaluation of the properties of cast metals and alloys. The presented platform is an extension of the SLAG - PROP application with new modules, which allow to use information on metallurgical processes in an even more effective way, as well as to evaluate the finished product. In addition, the construction of a measuring station for the analysis of thermal processes taking place in a metal bath allows for precise observation of phenomena together with their appropriate interpretation. The article presents not only the cooling curves of certain copper alloys. The analysis also covered mechanical properties related to hardness, finished products depending on the mold in which the products were cast. In the literature one can find information about the mechanical properties of products in the improved state, usually after plastic or thermal treatment, omitting their properties obtained as a result of a naturally made casting. The article also presents the method of placing information in the database using a convenient graphical tool.
5
Content available Reconstruction of the Casting Technology in the Bronze Age on the Basis of Investigations and Visualisation of Casting Moulds
Garbacz-Klempka A., Kwak Z., Żak P. L., Szucki M., Ścibior D., Stolarczyk T., Nowak K.
Archives of Foundry Engineering
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2017
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Vol. 17, iss. 3
184--190
EN
During excavation of the cremation cemetery of urnfield culture in Legnica at Spokojna Street (Lower Silesia, Poland), dated to 1100-700 BC, the largest - so far in Poland – a collection of casting moulds from the Bronze Age was discovered: three moulds for axes casting made out of stone and five moulds for casting sickles, razors, spearhead and chisels, made out of clay. This archaeological find constituted fittings of foundrymen’s graves. In order to perform the complete analysis of moulds in respect of their application in the Bronze Age casting technology analytical methods, as well as, computer aided methods of technological processes were used. Macroscopic investigations were performed and the X-ray fluorescence spectrometry method was used to analyse the chemical composition and metal elements content in mould cavities. Moulds were subjected to three-dimensional scanning and due to the reverse engineering the geometry of castings produced in these moulds were obtained. The gathered data was used to perform design and research works by means of the MAGMA5 software. Various variants of the pouring process and alloys solidification in these archaeological moulds were simulated. The obtained results were utilised in the interpretation of the Bronze Age casting production in stone and clay moulds, with regard to their quality and possibility of casting defects occurrence being the result of these moulds construction. The reverse engineering, modelling and computer simulation allowed the analysis of moulds and castings. Investigations of casting moulds together with their digitalisation and reconstruction of casting technology, confirm the high advancement degree of production processes in the Bronze Age.
6
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.
7
Content available Coordinated Production Planning and Scheduling Problem in a Foundry
Stawowy A., Duda J.
Archives of Foundry Engineering
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2017
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Vol. 17, iss. 3
133--138
EN
In the paper, we present a coordinated production planning and scheduling problem for three major shops in a typical alloy casting foundry, i.e. a melting shop, molding shop with automatic line and a core shop. The castings, prepared from different metal, have different weight and different number of cores. Although core preparation does not required as strict coordination with molding plan as metal preparation in furnaces, some cores may have limited shelf life, depending on the material used, or at least it is usually not the best organizational practice to prepare them long in advance. Core shop have limited capacity, so the cores for castings that require multiple cores should be prepared earlier. We present a mixed integer programming model for the coordinated production planning and scheduling problem of the shops. Then we propose a simple Lagrangian relaxation heuristic and evolutionary based heuristic to solve the coordinated problem. The applicability of the proposed solution in industrial practice is verified on large instances of the problem with the data simulating actual production parameters in one of the medium size foundry.
8
Content available Shrinkage Porosity Criterion and Its Application to A 5.5 Ton Steel Ingot
Zhang C., Bao Y., Wang M., Zhang L.
Archives of Foundry Engineering
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2016
|
Vol. 16, iss. 2
27--32
EN
In order to predict the distribution of shrinkage porosity in steel ingot efficiently and accurately, a criterion R√L and a method to obtain its threshold value were proposed. The criterion R√L was derived based on the solidification characteristics of steel ingot and pressure gradient in the mushy zone, in which the physical properties, the thermal parameters, the structure of the mushy zone and the secondary dendrite arm spacing were all taken into consideration. The threshold value of the criterion R√L was obtained with combination of numerical simulation of ingot solidification and total solidification shrinkage rate. Prediction of the shrinkage porosity in a 5.5 ton ingot of 2Cr13 steel with criterion R√L>0.21 m･℃1/2･s-3/2 agreed well with the results of experimental sectioning. Based on this criterion, optimization of the ingot was carried out by decreasing the height-to-diameter ratio and increasing the taper, which successfully eliminated the centreline porosity and further proved the applicability of this criterion.
9
Content available Modelling and Optimization of Organization of Workplaces in a Foundry
Kukla S.
Archives of Foundry Engineering
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2016
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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.
10
Content available Methods of Computational Intelligence in the Context of Quality Assurance in Foundry Products
Rojek G., Regulski K., Wilk-Kołodziejczyk D.
Archives of Foundry Engineering
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2016
|
Vol. 16, iss. 2
11--16
EN
One way to ensure the required technical characteristics of castings is the strict control of production parameters affecting the quality of the finished products. If the production process is improperly configured, the resulting defects in castings lead to huge losses. Therefore, from the point of view of economics, it is advisable to use the methods of computational intelligence in the field of quality assurance and adjustment of parameters of future production. At the same time, the development of knowledge in the field of metallurgy, aimed to raise the technical level and efficiency of the manufacture of foundry products, should be followed by the development of information systems to support production processes in order to improve their effectiveness and compliance with the increasingly more stringent requirements of ergonomics, occupational safety, environmental protection and quality. This article is a presentation of artificial intelligence methods used in practical applications related to quality assurance. The problem of control of the production process involves the use of tools such as the induction of decision trees, fuzzy logic, rough set theory, artificial neural networks or case-based reasoning.
11
Content available Application of ALSV(FD) logic and XTT knowledge representation in the range of ADI properties
Regulski K., Wilk-Kołodziejczyk D., Rojek B., Kluska-Nawarecka S., Adrian W. T.
Archives of Foundry Engineering
|
2016
|
Vol. 16, iss. 2
75--78
EN
The objective of studies presented in this publication was structuring of research knowledge about the ADI functional properties and changes in these properties due to material treatment. The results obtained were an outcome of research on the selection of a format of knowledge representation that would be useful in further work aiming at the design, application and implementation of an effective system supporting the decisions of a technologist concerning the choice of a suitable material (ADI in this case) and appropriate treatment process (if necessary). ALSV(FD) logic allows easy modelling of knowledge, which should let addressees of the target system carry out knowledge modelling by themselves. The expressiveness of ALSV (FD) logic allows recording the values of attributes from the scope of the modelled domain regarding ADI, which is undoubtedly an advantage in the context of further use of the logic. Yet, although the logic by itself does not allow creating the rules of knowledge, it may form a basis for the XTT format that is rule-based notation. The difficulty in the use of XTT format for knowledge modelling is acceptable, but formalism is not suitable for the discovery of rules, and therefore the knowledge of technologist is required to determine the impact of process parameters on values that are functional properties of ADI. The characteristics of ALSV(FD) logic and XTT formalism, described in this article, cover the most important aspects of a broadly discussed, full evaluation of the applicability of these solutions in the construction of a system supporting the decisions of a technologist.
12
Content available Applicability of Business Rules to Production Management in Foundries
Stawowy A., Duda J., Wrona R.
Archives of Foundry Engineering
|
2016
|
Vol. 16, iss. 1
85--88
EN
The size and complexity of decision problems in production systems and their impact on the economic results of companies make it necessary to develop new methods of solving these problems. One of the latest methods of decision support is business rules management. This approach can be used for the quantitative and qualitative decision, among them to production management. Our study has shown that the concept of business rules BR can play at most a supporting role in manufacturing management, but alone cannot form a complete solution for production management in foundries.
13
Content available The Implementation of Computer Platform for Foundries Cooperating in a Supply Chain
Wilk-Kołodziejczyk D., Kluska-Nawarecka S., Rojek G., Regulski K.
Archives of Foundry Engineering
|
2014
|
Vol. 14, iss. 3
111--116
EN
This article presents a practical solution in the form of implementation of agent-based platform for the management of contracts in a network of foundries. The described implementation is a continuation of earlier scientific work in the field of design and theoretical system specification for cooperating companies [1]. The implementation addresses key design assumptions - the system is implemented using multi-agent technology, which offers the possibility of decentralisation and distributed processing of specified contracts and tenders. The implemented system enables the joint management of orders for a network of small and medium-sized metallurgical plants, while providing them with greater competitiveness and the ability to carry out large procurements. The article presents the functional aspects of the system - the user interface and the principle of operation of individual agents that represent businesses seeking potential suppliers or recipients of services and products. Additionally, the system is equipped with a bi-directional agent translating standards based on ontologies, which aims to automate the decision-making process during tender specifications as a response to the request.
14
Content available The Decision Support System in the Domain of Casting Defects Diagnosis
Wilk-Kołodziejczyk D., Rojek G., Regulski K.
Archives of Foundry Engineering
|
2014
|
Vol. 14, iss. 3
107--110
EN
This article presents a computer system for the identification of casting defects using the methodology of Case-Based Reasoning. The system is a decision support tool in the diagnosis of defects in castings and is designed for small and medium-sized plants, where it is not possible to take advantage of multi-criteria data. Without access to complete process data, the diagnosis of casting defects requires the use of methods which process the information based on the experience and observations of a technologist responsible for the inspection of ready castings. The problem, known and studied for a long time, was decided to be solved with a computer system using a CBR (Case-Based Reasoning) methodology. The CBR methodology not only allows using expert knowledge accumulated in the implementation phase, but also provides the system with an opportunity to "learn" by collecting new cases solved earlier by this system. The authors present a solution to the system of inference based on the accumulated cases, in which the main principle of operation is searching for similarities between the cases observed and cases stored in the knowledge base.
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 Mathematical Programming for Lot Sizing and Production Scheduling in Foundries
Duda J., Stawowy A., Basiura R.
Archives of Foundry Engineering
|
2014
|
Vol. 14, iss. 3
17--20
EN
The problem considered in the paper is motivated by production planning in a foundry equipped with the furnace and casting line, which provides a variety of castings in various grades of cast iron/steel for a large number of customers. The quantity of molten metal does not exceed the capacity of the furnace, the load is a particular type of metal from which the products are made. The goal is to create the order of the melted metal loads to prevent delays in delivery of goods to customers. This problem is generally considered as a lot-sizing and scheduling problem. The paper describes a mathematical programming model that formally defines the optimization problem and its relaxed version that is based on the conception of rolling-horizon planning.
17
Content available Heuristic Model of the Mechanical Properties of a Hypoeutectic EN AC-42100 (EN AC-AlSi7Mg0.3) Silumin Alloy Subjected to Heat Treatment
Górny Z., Kluska-Nawarecka S., Czekaj E., Wilk-Kołodziejczyk D., Saja K.
Archives of Foundry Engineering
|
2014
|
Vol. 14, iss. 4
35--38
EN
The object of the experimental studies was to determine the mechanical properties of a hypoeutectic EN AC - 42100 (EN ACAlSi7Mg0,3) silumin alloy, where the said properties are changing as a result of subjecting the samples of different types to solution treatment. An important aspect of the studies was the use type of device for the heat treatment. As a basic parameter representing the mechanical properties, the tensile strength of the metal (Rm) was adopted.
18
Content available Analysis of Thermal Stresses in Components of Pallets Operating in Furnaces for the Carburising Treatment
Bajwoluk A., Gutowski P.
Archives of Foundry Engineering
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2014
|
Vol. 14, iss. 1 spec.
175--180
EN
The study is devoted to an analysis of thermal stresses arising in the basic elements of pallets used in furnaces for the carburising treatment. The construction of a pallet was presented and an example of its operating cycle was described. Using finite element method, a simulation analysis of the kinetics of cooling and heating of selected pallet components was performed. The results obtained were verified experimentally and used as a basis for the analysis of thermal stresses generated in these components during their cooling.
19
Content available Optimization methods for lot-sizing problem in an automated foundry
Duda J., Stawowy A.
Archives of Metallurgy and Materials
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2013
|
Vol. 58, iss. 3
863--866
EN
In the paper we studied a production planning problem in a mid-size foundry that provides tailor-made cast products in small lots for a large number of clients. Assuming that a production bottleneck is the furnace, a mixed-integer programming (MIP) model is proposed to determine the lot size of the items and the required alloys to be produced during each period of the finite planning horizon that is subdivided into smaller periods. As using an advanced commercial MIP solvers may be impractical for more complex and large problem instances, we proposed and compared a few computational intelligence heuristics i.e. tabu search, genetic algorithm and differential evolution. The examination showed that heuristic approaches can provide a good compromise between speed and quality of solutions and can be used in real-world production planning.
PL
W pracy przedstawiono problem planowania produkcji w odlewni średniej wielkości, która dostarcza odlewy na zamówienie dla dużej liczby klientów. W takim problemie konieczne jest określenie wielkości partii produkcyjnej oraz ilości i gatunku metalu w każdym okresie skończonego horyzontu planowania, który jest podzielony na mniejsze podokresy. Przy założeniu, że wąskim gardłem jest piec do topienia metalu, zaproponowano programowanie całkowitoliczbowe mieszane (Mixed-Integer Programming - MIP) jako model planowania i harmonogramowania produkcji w odlewni. Jako że użycie zaawansowanych komercyjnych solverów może być niepraktyczne dla złożonych problemów, zaproponowano i porównano trzy heurystyki inteligencji obliczeniowej tj. tabu search, algorytm genetyczny i ewolucja różnicowa. Eksperymenty obliczeniowe wykazały, że algorytmy heurystyczne zapewniają zadowalającą szybkość i jakość rozwiązań.
20
Content available Identification of the Heat Transfer Coefficient in the Inverse Stefan Problem by Using the ABC Algorithm
Hetmaniok E., Słota D., Zielonka A.
Archives of Foundry Engineering
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2012
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Vol. 12, iss. 2s
27--32
EN
A procedure based on the Artificial Bee Colony algorithm for solving the two-phase axisymmetric one-dimensional inverse Stefan problem with the third kind boundary condition is presented in this paper. Solving of the considered problem consists in reconstruction of the function describing the heat transfer coefficient appearing in boundary condition of the third kind in such a way that the reconstructed values of temperature would be as closed as possible to the measurements of temperature given in selected points of the solid. A crucial part of the solution method consists in minimizing some functional which will be executed with the aid of one of the swarm intelligence algorithms - the ABC algorithm.
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