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Data analytics applied to sand casting foundry industries
Published in Paulo Jorge da Silva Bartolo, Fernando Moreira da Silva, Shaden Jaradat, Helena Bartolo, Industry 4.0 – Shaping The Future of The Digital World, 2020
F. Leal, H.F. Castro, A.R.F. Carvalho, H. Gouveia
The current scenario of foundry industry requires optimization of operational costs which can be achieved by i4.0 implementation (Kozłowski et al. 2019; Lewis 2016) namely with predictive analytics. Foundry is one of the oldest manufacturing methods encompassing multiple processes - moulding, melting, pouring, solidification, shot blasting, and fettling. There are distinct casting methods such as permanent mould casting, centrifugal casting, die-casting, investment casting, shell casting, and sand casting (Aramide et al. 2009). On one hand, sand casting (sand moulding) is widely used once it is one of the cheapest methods. On the other hand, sand casting is a complex method generating multiple casting rejections and, consequently, large amount of offscourings (Saikaew & Wiengwiset 2012). Regarding this scenario, we present a methodology to ensure the quality and efficiency of the sand circuit for iron casting industries. The methodology relies on multiple sensors as well as data analytics methods integrating multiple i4.0 concepts. In this case study, the sand circuit incorporates three steps: (i) pre-mixer; (ii) muller; and (iii) GSM sand laboratory. The pre-mixer has the role of cooling the sand, pre-preparing it for another moulding. Then, the muller prepares the sand, adding an appropriated amount of water. Finally, the GSM laboratory as a control system, measures the green sand features (humidity, compactability, and compression strength).
Metals
Published in Ronald M. Scott, in the WORKPLACE, 2020
Molten metals are cast (poured into molds) in a foundry. Since the early days of the industrial revolution, castings have been commercially made in steel and iron, bronze, and brass. More recently, other materials have been handled in this fashion. These include lightweight aluminum and magnesium, high-strength titanium, chromium, nickel, zinc, and a vast array of alloys.
Metals I: Metals Preparation and Manufacturing
Published in Ronald Scott, of Industrial Hygiene, 2018
Molten metals are cast (poured into molds) in a foundry. Since the early days of the industrial revolution castings have been commercially made in steel and iron, bronze, and brass. More recently other materials have been handled in this fashion. These include lightweight aluminum and magnesium, high strength titanium, chromium, nickel, zinc, and a vast array of alloys, mixtures of two or more metals. Foundries employ more than 200,000 workers in the U.S. Cast iron production employs more than half the workers, so foundries are often classified into two groups: ferrous (iron) and nonferrous (all the rest). Some foundries produce small numbers of castings, as for the building of specialized machinery, whereas others rapidly produce large numbers of identical products, as would be the case in automobile parts production.
Optimization of dry compressive strength of groundnut shell ash particles (GSAp) and ant hill bonded foundry sand using ann and genetic algorithm
Published in Cogent Engineering, 2019
Chidozie Chukwuemeka Nwobi-Okoye, Patrick Chukwuka Okonji, Stanley Okiy
Foundry is one of the principal areas of engineering production where cast components of engineering and general-purpose products are produced. Most moulds for the production of cast components are made of sand. But before they are used for sand moulds they are mixed with binders to make them stick firmly together. Some of these binders are toxic and pollute the environment. In this research, we developed an eco-friendly binder made with groundnut shell ash and anthill powder for the production of dry sand moulds for casting engineering components with intricate shapes. Before a dry sand mould could be used for casting it has to be strong enough. Making the mould strong would almost very likely make the mould costlier depending on the combination of mould production process parameters. Engineers usually want very strong moulds to be produced at minimum cost. We, therefore, developed a model for producing very strong moulds at optimum cost.
Low pressure casting technology and forming process analysis of metal mold based on ProCAST FEA procedure
Published in Mechanics of Advanced Materials and Structures, 2022
Shrinkage cavity, depression and porosity are common casting defects in foundry industry, which is primarily attributed to insufficient liquid feeding due to shrinkage of high-temperature liquid during the cooling process. However, such defects destroy the continuity of metal material and affect the casting quality. Consequently, such defects should be avoided in casting process. Figure 7 is the predicted defect site during the casting cooling, which characterizes the entire process of liquid metal from high-temperature liquid to low-temperature liquid.