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Analiza symulacyjna przepływu ciekłego metalu przez innowacyjną komorę reakcyjną w technologii wytwarzania żeliwa sferoidalnego i jej optymalizacja

100%

Małysza M. , Stefański Z.

Prace Instytutu Odlewnictwa

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2019

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tom Vol. 59, no. 1

37--51

PL

Odlewy z żeliwa sferoidalnego znajdują szerokie zastosowanie w wielu gałęziach przemysłu ze względu na swoje właściwości mechaniczne. Wytwarzanie tego gatunku materiału wymaga utrzymania reżimu technologicznego oraz czystości materiału wyjściowego. Z tego powodu stale rozwijane są metody wytwarzania oraz kontroli tego materiału. W niniejszej publikacji przedstawiona została nowa metoda sferoidyzacji i modyfikacji żeliwa w formie. Innowacją tej metody jest zastosowanie specjalnie opracowanej konstrukcji komory, w której zachodzi reakcja uszlachetniania żeliwa. W artykule przedstawione zostały przeprowadzone badania symulacyjne, mające na celu analizę profilu przepływającego ciekłego metalu w zadanej konstrukcji. Następnie wprowadzone zostały zmiany geometrii komory, celem optymalizacji jej kształtu oraz powtórnie wykonano analizę w tożsamych warunkach brzegowych. Wynikiem badań jest opracowanie konstrukcji, która zapewni odpowiedni charakter przepływu pozwalający na uzyskanie dobrej jakości żeliwa i odlewów z żeliwa sferoidalnego w formie odlewniczej.

EN

Ductile iron castings are widely used in many industrial branches because of their mechanical properties. The production process of such a grade of cast iron requires the maintenance of the technological regime and the purity of initial charge material. For this reason, methods of manufacturing and controlling materials are constantly being developed. This publication presents a new method of modification and spheroidization in the mould. The innovation of this method is the use of specially developed construction of the reaction chamber. Simulation studies were conducted to analyze the flow profile of liquid metal in the developed shapes of the chamber. Subsequently, the changes in the geometry of the chamber were made and analyzed under the same boundary conditions. The result of the study is the designation of a structure that will provide the appropriate flow characteristics to achieve good quality castings.

2

Computer modelling of the ablation casting process and prediction of the strength properties of AC-42000 castings

61%

Małysza M. , Puzio S. , Major-Gabryś K. , Głowacki M. , Wilk-Kołodziejczyk D. , Kamińska J.

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tom Vol. 22, No. 2

79--88

EN

The demand for castings with superior properties has compelled the development and optimization of manufacturing technologies. By further developing already known techniques, we are able to contribute to the introduction of new research possibilities. The article presents the methodology of conducting simulation tests of the gravity casting process into sand moulds with the use of ablation. The ablation technique consists in spraying water through evenly spaced nozzles onto a mould into which the liquid casting alloy has been poured. The conducted research focuses on an alloy from the group of Al-Si alloys. In order to compare the effects of different techniques, additional tests were carried out for gravity casting into sand and metal die moulds. At the same time, virtual experiments were conducted to develop a simulation methodology for ablation casting technology, taking into account mould degradation. Additionally, the possibility of predicting the final mechanical properties of various manufacturing technologies was tested. Destructive tests were carried out to determine the mechanical properties in the cast samples, as well as microstructure tests and secondary dendrite spacing. The results of the mechanical tests are compared with the predicted simulation properties.

3

Developing a Methodology for Building the Knowledge Base and Application Procedures Supporting the Process of Material and Technological Conversion

51%

Wilk-Kołodziejczyk D. , Jaśkowiec K. , Bitka A. , Pirowski Z. , Grudzień-Rakoczy M. , Chrzan K. , Małysza M. , Doroszewski M.

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tom Vol. 67, iss. 3

1085--1091

EN

The article presents the developed IT solutions supporting the material and technological conversion process in terms of the possibility of using the casting technology of selected alloys to produce products previously manufactured with the use of other methods and materials. The solutions are based on artificial intelligence, machine learning and statistical methods. The prototype module of the information and decision-making system allows for a preliminary assessment of the feasibility of this type of procedure. Currently, the selection of the method of manufacturing a product is based on the knowledge and experience of the technologist and constructor. In the described approach, this process is supported by the proprietary module of the information and decision-making system, which, based on the accumulated knowledge, allows for an initial assessment of the feasibility of a selected element in a given technology. It allows taking into account a large number of intuitive factors, as well as recording expert knowledge with the use of formal languages. Additionally, the possibility of searching for and collecting data on innovative solutions, supplying the knowledge base, should be taken into account. The developed and applied models should allow for the effective use and representation of knowledge expressed in linguistic form. In this solution, it is important to use methods that support the selection of parameters for the production of casting. The type, number and characteristics of data have an impact on the effectiveness of solutions in terms of classification and prediction of data and the relationships detected.

4

Selection of casting production parameters with the use of machine learning and data supplementation methods in order to obtain products with the assumed parameters

51%

Wilk-Kołodziejczyk D. , Pirowski Z. , Bitka A. , Wróbel K. , Śnieżyński B. , Doroszewski M. , Jaśkowiec K. , Małysza M.

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tom Vol. 23, no. 2

art. no. e73, 2023

EN

The main purpose of the research, presented in this publication, was to develop methodology for the construction of predictive models which allow the selection of material production parameters for the material-technological conversion process. The development of prototype modules based on information-decision system allows an initial assessment of the level of feasibility of undertaking this type of operation. Algorithms 1, 2, 3 presented in the article were used to complete the missing data. The result of the algorithm enabled the creation of a data table that specifies the operation of the predictive models indicated in chapter 3 of this article. Entire work is presented with regard to the background of the ADI cast iron production process to locate the requirement where to apply the developed methods in the field of predictive algorithms and data completion algorithms. On the basis of developed methods and predictive algorithms, trial castings were operated.