To develop digital core production, three technology providers leading in their respective areas have successfully continued their long-standing partnership: MAGMA Gießereitechnologie GmbH (MAGMA), specialist in the virtual optimization of foundry processes, Hüttenes-Albertus Chemische Werke GmbH (HA), leading provider of foundry chemicals and Laempe Mössner Sinto GmbH (Laempe), renowned manufacturer of core production systems. The companies have now presented their progress.
Ensuring consistent quality during core production, which takes into account the interaction of various influencing factors and process variables, is particularly important when producing modern, complex castings. Whether the process is able to deliver 100% of the required quality can only be seen from the finished casting. It would therefore be very advantageous for foundries if possible deviations in the process were identified in advance in order to intervene at an early stage. Machine learning tools were used to establish quantitative correlations between the behavior of the molding material, the process status in the machine and the core quality.
Simulation during core production
The simulation-based mapping of core production enables exactly that. It makes the process transparent and predictable and takes into account as many process parameters as possible. Integrating these methods into the production environment is the vision that drives the partnership between HA, MAGMA and Laempe. Machine learning tools were used to establish quantitative correlations between the behavior of the molding material, the process status in the machine and the core quality.
Perspectives of the concept
“With this patented new tool, we have managed to combine process simulation and real core production. By coupling the time-dependent mold material properties with the core shooting machine and the current tooling, we can simulate the entire process holistically. In this way we ensure reliable core quality. Thanks to the short computing times, it is even possible to integrate the simulation into the real-time operation of the machine. We are also implementing this technology as a front-end predictor in MAGMA C+M, our core manufacturing process simulation software,” said Dr. Ingo Wagner, product manager core manufacturing processes at MAGMA GmbH.
“For Laempe, this cooperation is an important building block in our digitalization initiative, which we support with our Laempe Digital Cockpit software and our real-time inspection system Core Vision. The connection now established between process data, machine control and the finished core distinguishes this approach from many 'Industry 4.0 measures' in a foundry, where the connection to product quality is missing," adds Rudolf Wintgens, Managing Director of Laempe.
Pressure measurements from the core shooting machine can be used to predict core quality.
Use of AI technology
For the next step, HA carried out an extensive series of tests on a fully instrumented core shooting machine in order to link the behavior of molding materials with the virtual system. The latest AI technologies have been used to establish a robust predictive capability between the condition of the molding material at different machine settings and the final core quality.
“We can now detect core defects that are not visible to the naked eye but cause problems further down the process chain. Deformations during core storage, core breakage during casting and casting defects are often caused not only by the binder itself, but also by parameters such as the storage time of the molding material. A fresh molding material mixture flows better, can be compacted better and ensures less tool wear and ventilation problems,” explains Amine Serghini, member of the HA management team.
The virtual core shooting machine can be used to predict whether a molding material can still be used without causing subsequent problems or how production can be stopped to ensure good core quality.
During tests at the HA Center of Competence (CoC) in Baddeckenstedt, the empirical data on which the direct simulations are based were collected on a state-of-the-art Laempe core shooting machine used there. With this data, important influencing parameters and their effects on the casting process in the machine and in the tool can be precisely modeled. The CoC is equipped with a wide range of technical options and offers a valuable platform for partners from different specialist areas, whereby innovations are systematically advanced in joint development projects.
Thanks to the partnership between MAGMA, HA and Laempe, the technical implementation of a real-time capable, physical and data-based core production control has become a reality and represents a big step towards Foundry 4.0. This approach opens up new opportunities for all three partners to provide their customers with intelligent solutions at any time to offer optimized and robust core production.
