MYUNGHO KIM(M.Met.,Ph.D.) Inha University, Korea · ※ limitations in simple3. R (Reduce, Reuse,...
Transcript of MYUNGHO KIM(M.Met.,Ph.D.) Inha University, Korea · ※ limitations in simple3. R (Reduce, Reuse,...
MYUNGHO KIM(M.Met.,Ph.D.)Inha University, Korea
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Sequence of Presentation
1. Progress & Present Status of the Foundry Industry
2. Problems of the Foundry Industry & Suggested Solutions
3. New Growth Strategy for the Foundry Industry
4. Structure of Value Chain in Foundry Industry
5. Innovations in the Foundry Industry
6. Concluding Remarks
Progress of Foundry Industry
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Casting is one of the oldest metal forming process.At the early stage(BC4500), the foundry shop mainly produced simple weapons, such as arrowhead/swords.
Progress of Foundry Industry
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A cottage industry produced agricultural tools/ornaments
Progress of Foundry Industry
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Small size modern casting factories
Progress of Foundry Industry
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mechanized & automated modern foundry factories
Progress of Foundry Industry
- Enlarged/modernized furnaces & ladles-The capacity of largest induction furnace is now reached about 65 tons
Progress of Foundry Industry
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A variety of cast items from the modern foundry industry
Progress of Foundry Industry
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The largest cast component (weigh in excess of 320 tones) manufactured by Sheffield Forgemasters International (SFIL)
The largest cast component (2015)
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China U.S. India Japan Germany Russia Brazil Korea Italy France0
10
20
30
40
50
Cas
ting
Prod
uctio
n (m
illio
n to
ns) Casting Production in 2012
(Ref. - Modern Casting, Dec. 2013)42.5
12.89.34
5.34 5.21 4.30 2.86 2.44 1.96 1.80
World Foundry Production
46.2
12.010.0
5.44 5.25 4.20 2.74 2.63 2.02 1.73
- The amount of annual world foundry production is now reached over 100M. Tons.- The portion of iron & steel cast products is more than 80 %- China has produced nearly 50 % of the world foundry production.
Progress of Foundry Industry
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Problems of Foundry Industry
The foundry industry has made a great progress to support the modern civilization, but resulted in a pile of problems to threaten the future of the industry.
1. Huge energy consumption problems for melting process
2. Environmental problems by casting process
3. Problems in recruit of young generation due to 3D environment
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Training & Education
Suggested solutions for foundry Problems
Huge Energy consumption problems for melting process
Environmental problems by casting process
Problems in recruit of young generation due to 3D environment
Efficient use of energy
Green Foundry
Reuse of waste heat Clean scrap melting, Lighting, Compressed air, Air handling
Minimize emissionsEfficient use of raw materials Optimum utilization of process chemicals, Substitution of harmful substances
Revive World Skill Competition-boosting of the training-standardization & level-up
The eventual solution is to make workplace to feel-like working
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New Growth Strategy for Foundry Industry
- A reshuffle of the Value Chain in foundry industry- Convergence between industries and technologies
1. the restructuring of value chain become one of the crucial factors for sustaining the competitiveness in manufacturing.
2. the convergence technologies play an important role to raise the value added in critical segment within the VC.
Strengthening Competitiveness
Sustainable Foundry Industry with competitiveness
Structure of Value Chain in Foundry Industry
Raw Materials
Comp. Spec. Additive Insert
Slag Remove
Sampling
Chem. Analy.
Debris Removal
Lot No Sticking
Mold Assembly
Sand Ramming
Core Setting
Matching
Pattern
Sand
Additives
Mixing
SMC Measure
Tapping
Laddle
Slag Remove
Temp. Measur
Pouring
Inoculation
Shake Out
Cut Off
Shotting
Defect Check
Air Impact
Grinding
Hardness
Microscope
Mechanical Test
Rough M/C
Coating
Loading
Delivery
Raw Materials Melting
Sand Mixing
Metal Mold Molding Pouring Cooling & Post Treatment
Inspection Shipment
R.M.Certificate
Flowsheet of Casting Process
Mimetic Diagram for Value Chain of Casting
Design/Pattern
Raw & SubsidiaryMaterials
Facilities
Casting Operation Post Treatment Parts
BackwardIndustry
CastingForwardIndustry
Sand, Sleeve/Exothermic riserInoculants/FilterRefractories, Spheroidizer
Pig iron/Iron ScrapFerroalloy/R.E.MetalsNonferrous alloy(Al, Cu, Zn)
Molding M/CCore making M/CDust collecting M/C
Materials
Iron : Cast Iron, Ductile Iron, ADI
Steel : Cast Steel, Tool Steel, Special Steel
Nonferous : Al, Cu, Zn
Processes
Gravity castingMetall ic mold castingDiecastingPrecision castingCentrifugal castingSpecial casting(Full Mold process etc.)
Gate/Riser designCAD/CAEWooden pattern making
Inspection
GrindingCut-offSand reclamationShot blastingHeat treatmentSurface treatment
Defects inspection(X-ray, Ultrasonic etc.)Characteristic test(T.S., Elongation, Impact, Fatigue etc.)
Reliability test(NVH, environments etc.)
•Automobile parts•Aircraft parts•Transfer M/C parts•Construction equip parts
•Shipbuilding parts•Offshore support parts•Defense equip parts•Valve/fitting parts•Electronic equip parts(home appliance, mobile)
•Electricity parts•Power generator parts•Semiconductor equip parts
•Machine tool parts•Kitchen utensils•Furniture parts•Medical instrument parts
Final Products
Grinder, Cutter,Shot blasterHeat treatment M/CSurface treatment M/C
Furnace/LadleCaster, Cutter
Design/Pattern Making
• Conversion of 2D drawing3D drawing• Automatic pattern making (CAD, CAE)• Direct production of pattern by 3D Printing technology
Raw & Subsidiary Materials
Raw MaterialsPig iron/Iron Scrap, Ferroalloy/R.E.Metals, Nonferrous alloys(Al, Cu, Zn)
Subsidiary MaterialsSand, Sleeve/Exothermic riser, Inoculants/FilterRefractories, Spheroidizer, Binder
Casting Facilities
• Basic facility for foundry industryFurnace, Molding equipment, Sand Mixer, Cutter etc..
• Modern Foundry Industry has becomed mechanized, enlarged, and automated factory with high speed molding M/C, rapid melting furnace, and automated molding line.
Molding
Molding facility• Mixing M/C: sand + binder• Sand slinger, Disamatic molding M/C• Automatic high speed molding M/C
vertical moldinghorizontal molding
MeltingMelting furnace• Cupola is not popular nowadays, although it can produce
better quality iron melt• Electric furnace (resistance or induction heating) is used widely.• The capacity of the largest melting furnace is reached about 65 tons
Pouring
• Operating process of melt into mold• Most vulnerable time to produce defects, such as,
- occurrence of entrained dross /inclusions due to bad pouring operation - occurrence of pore defects/solidification shrinkage by inadequate pouring time.
• In pouring, manual, self-filling and robots filling are possible• For manual pouring, skilled persons are necessary
Shake Out/ Cut-Off• Shake out after solidification & cooling of cast• For noise reduction, enclosure systems are used for high noise unit operations
such as shake-out ,abrasive cutting, shot blasting and fettling.• As dust is produced during shake-out, closed room is recommended• Gates & risers are cut-off from the cast by hammer/gas/plasma cutting M/C
Post Treatments (fettling)• Post treatment means a series of processing to improve the surface quality,
properties and degree of size accuracy of the cast.• Shot blasting & shot pinning for clean the surface, • Heat treatment and surface treatment for improving the properties.• Sand reclamation is popular for the shake-out sand.
Inspection• Check the inside/outside defects and size accuracy for most cast products• PT, MT, RT, UT• 3-dimensional measuring instrument for accurate size measurement.
Packing/ Shipment• Deliver after proper packing• For effective management, we can introduce the concept of E.R.P.,
improved distribution process, and smart factory.
Value Chain of the Casting Process
From the reviewing of the structure of the Value Chain,
• Casting industry is not only consist of melting and pouring process.
• Casting industry is consist of large value chain connected with forward and backward industry ,such as planning and design of pattern, raw/subsidiary materials, foundry facilities, molding, shake out & cut-off, post treatment including grinding, reclamation of the shake-out sands, and inspection etc..
• For the successful progress and promotion of the casting industry, all the industries connected with the value chain of the casting industry must be developed together.
CPM for optimization of VC in foundry industryHighly value added cast product with low defect rates & high size accuracyVOC
Yield> 99 %
Strength> 800 MPa
Dimensionaccuracy< 0.5 mm
Thin wall< 2 mm
CFR : Critical functional response CTF : Critical to function
Thick wall> 1500 mmCTQ
I. Low defectsII. Higher value
added
Mfg. processes
Subprocesses
Rawmaterials& Parameters
CFR
CTF
CTF
Patternmaking
Mouldmaking
Melting & Casting
Heat/Posttreatment
Design
Machining
Mixing &Packing Moving &
Pouring
Curing MeltingMaterial
input
Solidification
MachiningHeattreatment
Blasting
Riser
Feeder
Gate
Runner
Material
Sand
Binder Pre-heating
Pouringtemp.
Meltingtemp. Master alloy
Inoculants
Nodularizer
Innovations for the foundry industry
1. Field supporting activities learned from the field experiences
2. R&D for core source technologies reflecting actual production lines
3. Manufacturing process change from 3D into ACE
4. Technology innovation by convergence with ICT technologies
5. Secure the solutions for the energy problems
6. Secure the solutions for the environmental problems
7. Support for the creation of good jobs
8. Continuous growth of industry by adopting 3D Printing technology
9. Construction of the advanced smart factory
Pass down of the production tech.
Junior Researcher
• Proof in R&D ability
Field experience
SeniorResearcher
Cowork
Bottlenech Tech
Field operation
R&D projects
Education and R&D support learned from field
continuous education
of the foundry techniques
Understand & support of
Bottleneck techniques
Deduction, fulfillment & distribution of R & D projects based on the field
Co-work at foundry field
Retired High career
Engineer
1.Field support activities learned from field experience
2. R&D for the core source technologies reflecting the actual production lines
SpectrometerQRP Pro server
Infrared Pyrometer
SMC
Foot Switch
Prodavis
RS232C
R485
MUX
Process/Quality
Control System Server
Batch Processing
of input Data
화학성분분석작업자 PC
엔지니어 PC
사물실 PC
대표이사 PC
Chemical Analyzer PC
Engineer PC
Office PC
CEO PC
Process/Quality Control Server
Process/Quality ControlServer ProgramProgram
TCP/IPProtocol
OS
MS SQL 2000 ServerDBMS
Windows 2000 ServerOff-line
On-line
Melting Molding Post Treatment InspectionScrap Insert
Melting
Tapping
Pouring
Core Molding
Molding
Core Assembly
Mold Assembly
Shake Out
Cut Off
Shot Blasting
Inspection
Grinding
Transportation
Final Inspection
Feed back
Feed back
Feed back
Feed back
Real Ti
me D
ata
Real Ti
me D
ata
Real Ti
me D
ata
Real Ti
me D
ata
3. Mfg. process change into ACE from 3D
Easy support
• automatic monitoring
• working robots
• automation
• System Integration• QRP
• minimize environmetal load• substitute production facility• develop clean technology
• optimize energy efficiency• process skipping production• simplify working process
Clean support
Automation support
4. Technology Innovation by Convergence with ICT Technology
Big Data IoT, Clouding System
Basic Technology for Convergence
Convergence
Improvement of Workmanship
Construction of Mfg. line based on ICT
Securing of Accuracy & Competitiveness
·
5. Secure the solutions for the energy problems
minimize the energy usage
Problems
Energy Efficiency Diversification of Energy Renewable Energy
• Following tendency to the traditional energy mix
• Energy guzzling industry with low efficiency
alternative melting methods Develop new processes using new & renewable energy
6. Secure solutions for environmental problems
ProblemsContinuous Problems of 3D Factors (dust/stink/noise/vib.)
※ limitations in simple 3R(Reduce, Reuse, Recycle)
e.g.
Reuse of pollutants
e.g. Reclamation of used sand
prevent production of pollutante.g. collection of dust/fume
Eco-friendly resources recovery
CO2 gas→artificial photosynthesis
(1) Passive Handling (2) Active Handling (3) Creative Handling
(Reduction) (Reuse) (natural recycling)
* 3D: Dirty, Dangerous, Difficult
7. Supports for the Creation of Good Jobs
Recruit of New Personnel
Make Workplace to feel like working
-The Point of manpower supply is not training
but attraction in work
- Preparation of incentive system with
working period
Strengthening of Employee’s
Ability
Education about convergence of
IT and Manufacturing Technology
- Introduce demand base Education System
Lifelong WorkingSystem
Lifelong working system for retired employee
- Planning, Preparation of guide book for work
- Training of technician by apprentice system
- Trouble Shooting & consulting
- Collaboration with Research Center/University
8. Adoption of the 3D printing for Continuous Growth of Foundry Industry
Changes in trend of manufacturing industry
Root Industry
Small QuantityBatch Production
FUTURE
Small VarietyMass Production
PRESENT
Individual Customized Production
3D Printingthe key technology for leading the changes
Traditional Industrial
Production
Evolution of Flexible Production Method for Small Quantity Batch Production
Realization of Ubiquitous Future Production Factory
Establishment of Leading Techniquesby Innovation and Industry Acceleration
Creation of Employment groundwork by New Paradigm of Manufacturing Industry
• Clouding Platform for Manufacturing • DB for Manufacturing Knowledge
• Business Model for Accompanied growth• Integration of Manufacturing & Service
Future FactoryTotal Solution
ICT Technology
High Dimensional Product & Process
Design (HDP2D)
Augmented Physical Production System
(APPS)
Global Standard/Certificate
serviceBase Technology
Service Technology
Manufacturing TechnologyProcess Design Technology
HDP2D :3D/4D Product/Process Design
APPS :- AR/VR-based Production- Extension of Cyber-Physical
Production System
9. Construction of Advanced Smart Factory
Concluding Remarks
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1. The foundry industry has made a great progress to support the modern civilization, but resulted in a pile of problems to threaten the future of the industry. Efficient use of energy and making a practical “Green Foundry Industry” are one of the answers to make the foundry industry to be sustainable.
2. For overcoming the labor shortage problem, eventually the workplace should become to feel like working. Revival of the metal casting event in World Skill Competition is necessary, and will result not only in boosting the training of young technicians but also in standardization and level-up of the quality of casting skills. For all these, the WFO should stand at the center and try to play the leading role.
3. For strengthening competitiveness of the foundry industry, we need to deeply discuss the innovation of the foundry industries, i.e. the restructuring of the value chain of the foundry industry and the convergence between industries and technologies.
.
감사합니다.