Inteligentno upravljanje, modeliranje i optimizacija procesa livenja
AuthorDučić, Nedeljko G.
Committee membersNikolić, Vlastimir
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In the framework of the doctoral dissertation, it is presented a development of control, modeling and optimization of the casting process, based on application of artificial i.e. computational intelligence methods. Improving of production processes in foundries, in the framework of researches that contains doctoral dissertation consist of modeling of metal melting process, optimization of sand casting system and control of gravity casting process. The first part of research deals with modeling of melting metal in furnaces. It is a complex process due to dynamics of non-linear chemical reactions. Conventional mathematical and thermodynamical models, which are certainly helpful, are not fully reliable due to complex interactions of process variables. Neural networks, as one of the key techniques of computational intelligence, are able to identify internal relationships through training examples. As such, they are used as an effective tool in defining the needed chemical c...omposition of the molten metal by providing alloying process improvement. Proper and complete mold filling is the main objective of the sand casting process, which ensures high quality of the casting part. To this end, the designs of the gating system and feeding system is of major importance, as improper designing of the system results in a number of defects in the casting process, e.g. low quality of the casting part. Тherefore, the gating system aims at providing a smooth, uniform and complete filling of the mold with pure, molten metal. Smooth filling eliminates turbulence, uniform filling ensures continuous mold filling, whereas complete filling allows the molten metal to reach minor, end cavities of the mold. During cooling casting part comes to the volume metal shrinkage, ie. reducing the volume of casting part. The importance of feeders is in their function to compensate the lack of molten metal in the casting part due to volume shrinkage. The second part of research is an optimal construction of gating system and feeders, which satisfy the requirements with high quality casting part and savings of materials. The combination of global optimization method and CAD/CAM software has provided the possibility of effective optimization, design and verification of optimal solutions by numerical simulation. Unlike some other industrial processes, many casting plants have not benefited from the advanced automation therefore the process of filling the mold cavity is still manually performed. Automated systems that minimize the participation of workers and enhance the precision of casting, are also the subject of research in this doctoral dissertation. The part of research, which is dedicated to the development of casting process control, contains a proposal of an automated system in casting plants, development of laboratory simulator of the casting process and the development of possibility of application of intelligent control of mold filling.