metal casting process merging with artificial intelligence

Prof. Baode Sun

孙宝德教授

Dean of School of Material Science &

Engineering, SJTU

上海交通大学材料学院院长，博士生导师

Metal Casting Process

– Merging with Artificial Intelligence

铸造—— 走向智能

铸造-走向智能

2019年6月20日

孙宝德

Metal Casting Process – Merging with Artifcial Intelligence

上海市先进高温材料及其精密成形重点实验室

Shanghai Key Lab of Advanced High-Temperature Materials and Precision Forming

目录

CO

NT

EN

TS

1. 铸造瓶颈问题The key Problem of Foundry

2. 走向智能铸造Towards Intelligent Casting

3. 数字化铸造是基础Digital Casting is the Foundation

4. 智能化铸造探索Exploration of Intelligent Casting

5

1.国际铸造产业发展状况与面临的问题

China:

49.4 million tons

India:

12.5 million tons

America:

9.6 million

tons

Europe:

13 million tons

Brazil:

2.2 million

tons2017年，全球铸件产量近1.1亿吨

global castings production reached nearly 110 million tons.

1. Development and problems of international foundry industry

铸造产业是“工业之母”

≈年消耗1亿吨标准煤，铸造能量的利用率１７％，能源与资源消耗多，碳排放高。The annual consumption of 100 million tons of standard coal, casting energy utilization rate is 17%, energy and

resources consumption, high carbon emissions.

≈3亿吨金属熔化量300 million tons of melt

The foundry industry is

"foundation of Industry"

6

2.Development and problems of China's foundry industry

45%

11%

9%

5%4%

5%

2%

2%

3% 2%11%

China

India

U.S.A

Japan

Russia

Germany

Brizil

Korea

France

Italy

Other

世界铸造大国

平均生产能力仅为德国的20%

全国 26000家，99%企业

年产万吨以下

现代化铸造企业＜10%

2017年

2.中国铸造产业发展状况与面临的问题

China produces 45% of casting products in the world, but compared with the developed countries, the

quality of casting products in China is still far behind the developed countries. The average production

capacity in China is only as large as 20% of Germany’s. There are about 26,000 foundries in China, and

99% of them have the capacity of less than 10,000 tons/year, and only 10% of them are modernized.

7

3.全球熔模铸造行业市场现状与发展趋势

0.00%

1.00%

2.00%

3.00%

4.00%

5.00%

6.00%

0

20

40

60

80

100

120

140

160

2011 2012 2013 2014 2015 2016 2017 2018

2011-2018年全球熔模铸造市场及规模增长率

（单位：亿美元，%）

市场规模（亿美元）同比增长（%）

航空领域达56亿美元

航空

39%

其他

19%

汽车

14%

医疗

17%

机械11%

全球熔模铸造市场应用分布

3. Current situation and development trend of global investment casting market

为满足熔模铸件“精、大、强”的品质要求，应发展的关键和支柱技术？The market of aviation sector is about $5.6 billion. How to meet the needs of the demanding from aviation

sector?

4.Current problems and the technical issues in foundry industry

2003-2018年中国铸件产量（万吨）和增长率（%）China's castings output (10,000 tons) and growth rate (%) from 2003 to 2018

中国铸造总量在4900万吨，因为铸造缺陷造成的损失约600亿。The total amount of foundry in China is 49 million tons, and the loss caused by casting defects is about 60 billion Yuan.

疏松Shrinkage

夹杂物inclusion

冷隔Cold lap

尺寸超差out of tolerance欠浇misrun

漏钢Breakout

4.目前铸造行业存在的问题及技术瓶颈

9

❑工艺出品率低 Low process yield

❑合格率低 Low qualified rate

❑精度低 Low dimensional accuracy

❑凝固缺陷多 Solidification defects

❑生产线孤岛多 Production islands

铸造走向何方？Where is casting going?

5.目前铸造存在的理论问题及技术瓶颈

铸造技术瓶颈The key Technology issue

❑形核与生长 Nucleation and growth

❑凝固中的解析解 Analytical Solution

❑缺陷形成准则 Defect Formation

❑微观组织Microstructure

❑相场法 Phase field method

❑模数法Modulus method

凝固理论发展Development of solidification theory

理论指导

实践验证

5. Current theoretical problems and the technical issues in foundry

theoretical guidance

practical verification

目录

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3. 数字化铸造基础Digital Casting is the Foundation


1.智能化与数字化改变传统铸造

1. Artificial Intelligence and Digitalization are Changing Traditional Casting

人工智能已经在面部识别，自动驾驶，甚至在传统认为程序难以

逾越的围棋领域大放异彩。Artificial Intelligence has been successful in facial

recognition, autonomous driving, and it even

beats top GO players that was not considered

possible many years ago.

铸造过程可以视作一个由多种因素影响的黑箱过程，通过分析大

量数据以及恰当的AI算法能掌握这个黑箱的规律，并且将规律用

于自我学习指导工艺设计。Casting process could be considered as a ‘black

box’ process. By analyzing big data and implement

proper AI algorithm, it is possible to master the

essence of the ‘black box’, and in return the casting

process can be optimized.

AlphaGo Zero 在“无（人类）监督下”完成学习与演进并超越人类。

Complete Learning and Evolution without Supervision and Beyond Human Beings

Fully Connected Layers

人工智能辅助理性设计铸造工艺

大数据处理输入参数vs.材料性能的数据轨迹

机器学习深度学习

掌握规律

材料性能

黑箱过程

2.智能铸造系统

浇铸系统如冒口,浇道设计对于铸件性能影响巨大。通过人工智能技术合理优化设计浇铸系统，既避免疏松等缺陷，又节省材料。Casting system including riser and runner has tremendous impact on the properties. AI is implemented to

optimize casting system to avoid casting defects, and save materials.

2. Intelligent Casting System

Artificial Intelligence Assisted Rational Design for Foundry Technology

❑ 凝固组织

❑ 凝固缺陷

❑ 力学性能

❑ 出品率

➢ 化学成分

➢ 铸造工艺

➢ 环境噪音

➢ 结构形状

模具／产品设计Mold design

铸造工艺参数Process

parameters

铸件性能／缺陷Casting defects

and properties

生产现场数据采集

AI Cast云端服务

人工智能算法

Algorithm

数据库Database

浇冒口智能设计Optimize casting

system

产线质量控制Quality control

铸造工艺优化Optimize

casting process

缺陷自动识别Defects

recognition

铸造企业接入云端服务器

2.智能铸造系统

2. Intelligent Casting System

铸造企业通过传感器与5G网络接入到AI cast

云端系统提供服务，云端系统获得的企业数据又进一步提高了算法的准确性。Foundries have access to AI

Cast via sensors and 5G

network and get services.

In return, the algorithm

can be improved by data

from foundries.

3.智能铸造装备与技术

“智能铸造”是数字化、信息化与铸造生产高度融合的产物。智能铸造系统是具有学习能力的大数据知识库，自我规划、自我改善。"Intelligent casting" is a product of high integration of

digitalization, informatization and casting production. Intelligent casting system is a large data knowledge base with

learning ability, self-planning and self-improvement.

虚拟铸造

Virtual casting

快速造型

Fast moulding

机器人应用

Robotics

缺陷识别

Defect Recognition智能铸造装备与技

术

3. Intelligent Casting Equipment and Technology

物理空间Physical space虚拟空间 Virtual space

机理模型数学模型

应用验证

分析目标

经验知识

工艺参数优化

装备产线可靠性

产线质量分析

迭代验证

4.铸造数字孪生技术

4. Foundry Digital Twin Technology

By making full use of the data of physical model, sensor update and operation history, the simulation process of multi-discipline,

multi-physical quantity, multi-scale and Multi-probability are integrated, and the mapping is completed in virtual space, thus

reflecting the corresponding life cycle process of physical equipment.

Analytical objectives

Experiential knowledge

Process optimization

Reliability of Equipment

Quality Analysis

Iterative verification

目录

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1. 铸造瓶颈问题Bottleneck Problem of Foundry




铸造系统数字化

产品数字化

工艺数字化

CAD:UG/Catia/PRO-E

CAE:Nastran/Ansys

PDM: Team-Center

ERP: SAP、Enovia

装备数字化

控制：NC,CNC,DNC

系统：MC,FMC,FMS

涉及装备与产品

的几何、力学行

为的耦合！

CAPP、DFX？

影响产品性能影响制造效率

影响制造效率影响制造质量

数字化铸造技术体系：铸件表达数字化、铸造装备数字化、铸造工艺数字化、铸造系统数字化。

1.数字化铸造技术体系

Digital casting technology system: casting expression digitalization, casting equipment digitalization, casting

technology digitalization, casting system digitalization.

1. Digital Casting Technology System

2.虚拟铸造技术

全过程误差流误差分析软件平台全流程位移场仿真计算平台

全流程虚拟集成计算与误差调控技术是铸件的尺寸精度控制有效路径。The whole process integrated calculation and error control technology is the digitized path of dimensional

accuracy control of castings.

2. Virtual Casting Technology

Simulation platform for displacement field for whole processSoftware platform for error flow and analysis in the whole process

全流程误差流数字化调控 3.数字化建模技术

◆ 数字化建模设计与稳健控制技

术：基于容差控制系数，构造

各阶段容差约束条件，并考虑

各阶段制造难度，多尺寸的综

合精度为目标，对各阶段进行

容差设计。

3. Digital Modeling Technology

◆ Tolerance design and robust control

technology: Based on tolerance control

coefficients, tolerance constraints are

constructed for each stage, and

tolerance design is carried out for each

stage taking into account the

manufacturing difficulty of each stage

and the comprehensive accuracy of

multi-dimension as the goal.

4.集成计算材料工程

微观组织计算显微缩松预测力学性能预测宏观模拟

ICME跨层次多尺度计算可构建高温合金铸件成分-组织-结构-性能-工艺的关系

通过了铸件成型流场，温度场，凝固缺陷与凝固组织的多尺度计算，构建了工艺-组织-性能关联关系（凝固参数-二次枝晶间距-显微缩松-强度与寿命），复杂铸件10个特征位置进行了验证，预测与实际晶粒尺寸平均相差8.45%。Through the multi-scale calculation of casting flow field, temperature field, solidification defects and

solidification structure, the process-structure-performance relationship (solidification parameters-secondary dendrite

spacing-micro shrinkage-strength and life) was constructed.

特征位置验证

4. Integrated Computing Materials Engineering

Ten characteristic positions of complex castings were verified, and the average difference between predicted and actual

grain size was 8.45%.multi-scale calculation of ICME can construct the relationship between composition, structure,

performance and process of superalloy castings.

基于SLS增材制造技术，制造周期较传统工艺缩短6倍以上。增材制造造型设备的数字化与智能化是实

现铸造过程智能化的关键技术。

5.装备数字化快速铸造技术

5. Equipment Digital Rapid Casting Technology

The digitalization and intellectualization of moulding equipment is the key to realize the

digitalization control of casting process. Based on SLS augmented material manufacturing

technology, short cycle and high efficiency casting forming. The manufacturing cycle is

more than 6 times shorter than that of traditional process.

目录

CONTENTS





30年代中期 Chvorinov 凝固模数

40年代末Caine J.B 凝固速率比法

60年代末 R.Woldawer铸件形态参数

1982年 Mcadams J. Q参数法

1995年周尧和提出周界商法

2000年高尚书三次方程解析法

2001年赵清和Δ参数法冒口设计

经验驱动的模型

1.浇冒系统智能优化技术

1. Intelligent optimization of gating system

Experience-driven model

riser design

人工智能算法冒口优化

冒口形状几何拓扑优化➢Riser optimization with artificial intelligence algorithm

➢Topology optimization for riser shape

冒口尺寸数据流自动优化计算流程与框架

智能铸造-冒口数字化智能化设计1.浇冒系统智能优化技术


Software flow

data flow

Framework for automatic optimization of riser size data flow

自动高通量计算

智能算法自动优化寻优

典型环套环铸件

Automatic high-throughput

calculation

Automatic optimization of

intelligent algorithm

Typical ring to ring

castings

采用数据挖掘算法对铸件缺陷位置和工艺出品率进行多目标寻优。铸件工艺出品率提升了14.49%，经模拟与浇注实验验证后，

铸件工艺出品率相差0.78%，算法优化精度可靠。Multi-objective optimization of casting defect location and process yield was

carried out by using data mining algorithm. The casting process yield has been increased by 14.49%. The simulation and pouring

experiments show that the difference of casting process yield is 0.78%. The optimization accuracy of the algorithm is reliable.

智能铸造-冒口数字化智能化设计1.浇冒系统智能优化技术


特征铸件实验验证

Experimental verification of typical castings

模拟验证simulation verification

模数法冒口riser with modulus method

优化算法冒口riser optimization algorithm

智能铸造工艺设计系统

浇注系统模具设计制壳参数收缩补偿率

工艺设计模型

浇注参数

铸造工艺分析铸件结构参数化

浇注系统参数化补缩系统参数化

Typical Structural Database

2.智能铸造工艺设计软件系统

2. Intelligent Casting Process Design Software System

Process design model

Analysis of casting process and structural parameterization

Parameterization of gating system

gating system

mold design

shell parameters contraction compensation rate

pouring parameters

超级平台模拟计算

上传铸件模型文件

上传计算参数文件下载模拟计算优化报告

无需购买软件即可在线使用本软件计算、分析服务。并在计算结束后，下载标准化文本和动画报告。This software can be used online

without purchasing. At the end of the calculation, the standardized text and animation report are downloaded.

3.智能铸造云平台

3. Intelligent Foundry Cloud Platform

Upload calculation parameter file

Upload Casting Model File

Submission

model

On-line

Computing

On-line

optimization

Super Platform Simulation

Download simulation and

optimization report

大数据技术体系逐渐成熟智能铸造工厂是大势所趋决策支撑

数据基础

传统铸造走向智能铸造已成为必然。It is inevitable for traditional casting to move towards

intelligent casting

结论与展望

Big data technology system is maturing Intelligent foundry is the trendData base

Decision support

CONCLUSION AND OUTLOOK

Thank you！

metal casting process merging with artificial intelligence

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