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258

CHINA FOUNDRY Vol.5 No.4

Sharing casting technological data on web site

*Sun Xun, Li Hailan, Wang Junqing, Piao Dongxue, Hou Gang, Guan Yang, Wang Penghua, Zhu Qiang and Xie Huasheng

(Shenyang Research Institute of Foundry, Shenyang 110022, Liaoning Province, P. R. China)

Abstract: Based on database and asp.net technologies, a web platform of scientific data in the casting technology fi eld has been developed. This paper presents the relevant data system structure, the approaches to the data collection, the applying methods and policy in data sharing, and depicts the collected and shared data recently fi nished. Statistics showed that there are about 20,000 visitors in China every day visiting the related data through the web, proving that many engineers or other relevant persons are interested in the data.

Key words: casting technology; data; sharing; webCLC number: TP392 Document code: A Article ID: 1672-6421(2008)04-0258-07

As a rapid means of carrying out process design, procedure management and acquirement of information about

modern industries, the database technology has got more and more applications, and in recent years, the technology application has also developed in foundry processes.

In 2006, the Die Casting Society of the UK had fi nished an intelligent foundry technology database and expert system based on the web technology [1]. It mainly serves for small and medium enterprises, and provides through the web the processes, materials, equipment, design parameters and technological services in the permanent mould casting, die casting, sand mould casting and lost-wax casting fi elds. The database systems collected the long term experience and knowledge of employees and are helpful to foundry business newcomers who are short of experience in skills learning and education. The database also provided all foundry-oriented permanent mould design procedures including tables, charts and graphs on materials and process properties the design needed. Moreover, all design decisions will be stored in database to serve as future references; the decision support system provided can be also used to generate the best route to manufacture a casting or tooling and a quotation according to the material, geometry information, technical specifications and product amount. The web based database systems covered the whole process of generating quotation, designing moulds and planning manufacturing. This gives end users estimate cost savings up to 20 % and time savings up to 35 %.

In 2002, the North American Die Casting Association

Male, born in March, 1964, PhD. Senior researcher. His study interests include casting processes, CAD/CAE, and special casting processes.E-mail: [email protected]: 2008-08-26; Accepted: 2008-09-29

*Sun Xun

(NADCA) launched an online Die Casting Technology Database [2] and the main contents include articles on the transactions of NADCA, papers of Die Casting Engineer magazines and NADCA research reports. Users can search for these references according to key words through the web.

Recently, the e-Design Center of KITECH is developing an Intelligent Expert System (IES) [3], which is a construction of foundry database and recognition technique for casting design. The foundry experts have been using industrial computer tomography to scan the castings, including casting design components: such as gating system, riser, overfl ow well, etc., and the scanned data are converted into three dimensional CAD data. Then, the results for castings and casting technology design are divided into different arrays and saved in the database. When a new casting technology is designed, the casting is compared with castings in the database by using pattern recognition software; the casting technology design stored in the database can be suggested as the fi rst stage of a new casting technology design. It is expected that the suggested casting technology designs could reduce modeling and designing time. This is the purpose of developing the IES. The IES continually collects vast amounts of data into the system.

Over the last ten years, the domestic relevant database developments have focused on the foundry information management [4], casting process CAD parameter database [5-7], foundry auxiliary equipment and tools database [8], thermal physical properties database of foundry materials [9-10], etc. However, most of them are auxiliary design means for one procedure of the casting processes, not integral systems.

The data provided on our web site includes digital data, documents, photos, engineering drawings, etc. The main goal of our study is how to share the foundry technological data logically on the web site and to take advantage of the composition of the above styles of presenting the data.

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Research & DevelopmentNovember 2008

1 The system structure design of foundry technological data

1.1 The system structure design of foundry technological data and service objectives

Based on the national and international developing experiences

Fig. 1 The structure of foundry technological data

in relevant fields, the integrating scheme of foundry technological data has been drawn up and the main data structure is shown in Fig. 1.

The sorting out focal points for scientific data in foundry technological field are equipment, materials, and process techniques with relation to castings forming. These include foundry materials, foundry facilities, melting technologies, casting processes, post-processing of castings, die casting technologies, foundry standards, etc. Moreover three columns were set up at the interface of the web site including foundry professional developments, new foundry technology, and foundry historical facts in modern and ancient times in China and foreign countries.

The service targets of the foundry technology data are staffs of government departments, university and college students, researchers in related research institutes, engineers and technicians in enterprises, technical workers, etc.

The contents in the resource system of foundry professional technology data are divided into fi ve layers of resource set and one layer of resource object.

1.2 The structure design of resource set layer and resource object layer

The design contents for three layers of the resource set are given in Fig. 1. Since the contents of the resource set layer are in great numbers, sample content is described as follows.

Resource object data are those that could not be divided further according to definition, so all the practical data users could read are in the resource object layer.

Casting forming processes include many sorts of data, and different data have different characteristics and rules of application, therefore the structure design of resource objects should be of different styles. For example, the structure design of the resource object layer follows the principle of combining real technological data with simple process descriptions for melting technologies, casting processes and post-processing of castings. The aim is to make it satisfactory for casting technological design habits of different users as much as possible, to make it convenient to inquire about and apply data for users. In addition, the accumulation of technological design files is very important. This is a summation of successful experience from predecessors and is also an effi cient tool for newcomers learning casting design. All of these are considered in the structure design. Various methods of data structure design are as follows.

(1) Foundry materials

The structure of the resource object layer of raw and auxiliary foundry materials is mainly a unit datum table

Foundry materials

Foundry Technology

Foundr

Melting technologies

y facilities

Casting processes

Post processin of castings

Die casting technologies

Foundry standards

Magnesium alloy die casing

Casting cleaning and repairing; Heat t reatment of casting; Quality of casing

Basis of casting processes; Sand mould casting; Permanent mould casting; Evaporative pattern casting

Cast iron melting; Cast steel melting; Non-ferrous alloys melting; Die casting alloy melting

General base and technologies; Molding materials; Cast iron; Pig iron and ferroalloy for casting; Cast steel; Cast non-ferrous alloys; Die casting alloys; Lost-wax casting

Sand preparation; Molding; Core making; Melting and pouring; Transportation and weighting; Special casting processes; Shakeout; Cleaning; Inspection and control; Environment protection; other auxiliary equip

Raw and auxiliary foundry materials; Casting alloy materials

gg

ments

260


of name, index of major properties and usage for different raw and auxiliary foundry materials; together with a table of composition, limiting quantities of impurity elements, mechanical properties, physical properties, chemical properties and grade comparison for various casting alloys.

Foundry users are able to search the relevant technical index according to a casting alloy grade given in the blueprint of parts and to select moulding materials according to the requirements given in casting technological design drawings.

(2) Foundry facilitiesThe structure of the resource object layer of foundry

facilities is mainly a unit datum table with information of specifi c type; and indices of properties, outer dimension sizes of different equipment and apparatus.

(3) Melting technologiesA structure design example of the resource object layer of

melting technology is shown in Table 1, which is a unit datum table constructed by taking alloy grade as index.

(4) Casting processTaking the structure of sand casting process design data for

steel casting as an example, its content of 4th and 5th set layers are given in Fig. 2. One example of resource object layer is the feeding distance that is shown in Fig. 3.

(5) Post-processing of castingsThe resource object layer of post-processes of castings

are mainly unit datum tables on welding and heat treatment

according to the grade of casting alloy materials. In addition inspection methods for internal quality and surface quality of castings, cleaning and repairing methods for castings, etc., are included.

(6) Die casting technologiesThe resource set layer mainly contains magnesium alloy die

casting technology. In the resource object layer the relative technical data are given for technological designs of die casting, die designs, parameters of die casting technology, defects of die casting, protective measures, etc.

(7) Foundry standards In the resource object layer of foundry standard the names

and numbers of national standards related to the casting formation are given. Users are able to obtain the real contents of standards from relevant departments according to the names and numbers of standards.

2 Data source and collecting approaches

2.1 Data sourceThe data source of foundry technology consists of foundry handbooks, journals and magazines related to foundry techniques, casting monographs, casting patents, scientific research achievements in the foundry field as well as accumulated files of casting process design in foundry enterprises.

Table 1 Melting technology of cast brass alloy

AlloyMeltingscheme

Meltingequipment

Main points in the melting process

ZCuZn16Si4 Once meltedMiddle frequency

furnace

1. A crucible is preheated to 500-600°C, all of the electrolyzed copper plates

are put into the crucible, covered with crumbled graphite up to about 0.5%

– 2% of the weight of the furnace charge. If foundry returns are used, the

charging sequence should be Cu→Si→foundry returns→Zn.

2. Heating and melting the furnace charge and overheating to 1,200 °C.

3. The copper melt is deoxidized by Cu-P alloy with the amount of P making up

0.003% – 0.006% of the whole copper melt weight.

4. Pressing the preheated industrial silicon in batches, and then stirring.

5. Zinc, preheated to 200 – 300 °C, is added in batches, stirring the melt for

each batch. When all the zinc has been added, the melt is stirred again.

6. Heating the melt at the boiling point for 1-2 minutes.

7. Taking a sample to analyze chemical composition of melt, and calculating

the additional amounts of different elements according to the results of the

analysis.

8. Both the tapping temperature and pouring temperature are 1,050 –1,150 °C.

After fi nishing the examination, remove the slag and tap.

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Fig. 2 Contents of 4th and 5th set layers of casting processes for sand mould steel castings, and the 4th set layer without contents of the 5th set layer is connected directly with the resource object layer

Fig. 3 An example of the structure of the resource object layer for sand casting of steel alloy

Content and steps of casting process design for sand mold casting

Creation of casting drawing

Analyzing solid geometry of casting

Scheme and parameter of casting process

Sand core design

Content of sand mold casting design, step of sand mold casting design

Modulus calculation of divided body of casting, casting weight calculation

Riser disposing, feeding distance of riser, pad design, chill design, calculating riser size

Core setting, core fixing, core positioning, size and clearance of core print, chaplet, core rod, core gas venting, putting together and pre-assembly

Determining pouring position, deciding parting face, linear contraction rate of casting and linear enlarging rate of pattern, pattern draft, negative allowance of non-machining wall thickness, deformation allowance in reverse, molding allowance, parting a llowance, cutting allowance of r iser and ingate, mold cooling time of casting

Casting design, dimensional tolerance of casting, machining allowance, ribs, cast smallest hole and groove

Mold assembly

Core setting, mold assembling and positioning, force of closing mold and fastening, allowing wait time for pouring after closing mold

Feeding system design

Sand mould casting design database Steel casting b y sand mold, iron casting b y sand mold, and copper

casting by sand mold

Gating system design

Foundry processing drawing

Technical process card

Vent design

Mold and core making

Green sand molding by machine, molding and core making by self-hardening resin sand, molding and core making by sodium silicate bonded sand, dry sand mold, skin dried mold, hand molding, classification and selection of core making, baking of mold and core

Casting process symbol, example of casting process figure

Resource object layer

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2.2 Data collecting approaches The data collecting, integrating and sorting processes are carried out according to “Quality control norm of scientific data in advanced manufacturing and automation region” and “Unit datum standard of scientific data in advanced manufacturing and automation region”, which were worked out by project group and the data are divided into seven grades to be filled in unit datum tables. The integrated and sorted data are input using a recording software system SJGX 6.0, developed based on asp.net technique, which is shown in Fig. 4. The data will be shared in batch and different time on “www.amadata.net.cn” platform.

Fig. 4 Data recording software system

3 Collection and integrated data and relevant application

Besides setting up a web site on the Internet and constructing a data structure system of foundry technological field, the content completed up to now for integrating, sorting and sharing data includes data of new foundry techniques, foundry materials, foundry facilities, melting technologies of cast steel, cast iron and copper alloys, permanent mould casting process, evaporative pattern casting process, etc. The data being input consists of casting process data of sand mould casting for cast steels, cast iron and cast copper alloys, post processing data of castings, melting technology data of cast steel, cast iron and cast copper alloys. Examples for getting parameters of melting carbon steel ZG 200-400, inquiring into foundry technological data and sharing them are shown in Fig. 5 and Fig. 6. Since users are mainly in China, a web platform of casting technology data has been constructed in Chinese.

There are about 20,000 persons in China visiting the web site every day, and some of them are interested in foundry

technologies. The data now integrated, sorted and being shared have been applied to casting formation of titanium alloys, aluminum alloys, and copper alloys; as well as melting and casting formations of cast steel alloys, which have played important roles in national key engineering fi elds.

4 Conclusions(1) The structure system for the scientific data of casting

technological fi eld has been constructed, and part of the data has been shared on the web site.

(2) Integrating, sorting and sharing data have been applied in the engineering fi eld of casting formation, and there are about 20,000 persons visiting the web site every day.

(3) The constructed web site of scientifi c data of the casting technological field has actively promoted rapid exchanging of national casting technological information and foundry professional development.

References[1] The Diecasting Society News. A Significant Step in Tooling.

Cast Metal & Die-casting Times. 2006, 8(5): 32.[2] Metalcasting News. NADCA Launches Online Database.

Foundry Management & Technology. 2002, 130(4): 10.[3] In-Sung Cho, Seung-Mok Yoo, Chae-Ho Lim and Jeong-

Kil Choi. Database Construction for Casting Design by Using Industrial Computer Tomography. The 1st Korea-Sino Advanced Computer Modeling Conference for Manufacturing Technologies, Inchon, Korea. Sept., 2006.

[4] Qiu Zhongwen, Chou Chunli, et al. Application of database technology to foundry industry. Foundry, 2003(1): 45-48. (in Chinese).

[5] Hu Hongjun and Zhang Chi. Research and development on database of foundry technological CAD parameters. Foundry Technology, 2004(9): 695-696. (in Chinese).

[6] Wang Yunai and Shen Bingzhen. Application of relative standards in the database integrating process of foundry technological CAD system. Hot Working Technology, 2004(1): 47-49. (in Chinese).

[7] Wang Yunai and Xu Qingyan. Engineering database of foundry technological CAD and its integrating method & way. Hot Working Technology, 2002 (2): 50-52. (in Chinese).

[8] Zhang Jingfang, Wang Taihui, et al. Database management of foundry tooling and CAD system development. Research Studies on Foundry Equipment, 2002(4): 28-30. (in Chinese).

[9] Yang Bingjian, Wang Liqin and Wei Biao. Development of management system for thermal properties database of foundry materials. Foundry Technology, 1998(6): 9-11. (in Chinese).

[10] Wang Xijun and An Geying. Development and research of database system for foundry thermal properties. China Foundry Machinery & Technology, 1998(1): 1- 13. ( in Chinese).

This work is supported by project of “Advanced Manufacturing and Automation Database on Web Site” in scientific data sharing engineering, which is sponsored by The Ministry of Science and Technology of the People’s Republic of China (Project No. 2005 DKA32900)

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Fig. 5 Inquiring into foundry technological data of melting technology on web site

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Fig. 6 Sharing parameters of melting carbon steel ZG 200-400 on web site

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