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Abstract

One way to ensure the required technical characteristics of castings is the strict control of production parameters affecting the quality of

the finished products. If the production process is improperly configured, the resulting defects in castings lead to huge losses. Therefore,

from the point of view of economics, it is advisable to use the methods of computational intelligence in the field of quality assurance and

adjustment of parameters of future production. At the same time, the development of knowledge in the field of metallurgy, aimed to raise

the technical level and efficiency of the manufacture of foundry products, should be followed by the development of information systems

to support production processes in order to improve their effectiveness and compliance with the increasingly more stringent requirements

of ergonomics, occupational safety, environmental protection and quality. This article is a presentation of artificial intelligence methods

used in practical applications related to quality assurance. The problem of control of the production process involves the use of tools such

as the induction of decision trees, fuzzy logic, rough set theory, artificial neural networks or case-based reasoning.

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Authors and Affiliations

S. Kluska-Nawarecka
K. Regulski
G. Rojek
D. Wilk-Kołodziejczyk
K. Jaśkowiec
A. Smolarek-Grzyb
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Abstract

The structure of Austempered Ductile Iron (ADI) is depend of many factors at individual stages of casting production. There is a rich literature documenting research on the relationship between heat treatment and the resulting microstructure of cast alloy. A significant amount of research is conducted towards the use of IT tools for indications production parameters for thin-walled castings, allowing for the selection of selected process parameters in order to obtain the expected properties. At the same time, the selection of these parameters should make it possible to obtain as few defects as possible. The input parameters of the solver is chemical composition Determined by the previous system module. Target wall thickness and HB of the product determined by the user. The method used to implement the solver is the method of Particle Swarm Optimization (PSO). The developed IT tool was used to determine the parameters of heat treatment, which will ensure obtaining the expected value for hardness. In the first stage, the ADI cast iron heat treatment parameters proposed by the expert were used, in the next part of the experiment, the settings proposed by the system were used. Used of the proposed IT tool, it was possible to reduce the number of deficiencies by 3%. The use of the solver in the case of castings with a wall thickness of 25 mm and 41 mm allowed to indication of process parameters allowing to obtain minimum mechanical properties in accordance with the PN-EN 1564:2012 standard. The results obtained by the solver for the selected parameters were verified. The indicated parameters were used to conduct experimental research. The tests obtained as a result of the physical experiment are convergent with the data from the solver.
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Authors and Affiliations

K. Jaśkowiec
1 2
ORCID: ORCID
A. Opaliński
2
ORCID: ORCID
P. Kustra
2
D. Jach
3
D. Wilk-Kołodziejczyk
1 2
ORCID: ORCID

  1. Lukasiewicz Research Network-Krakow Institute of Technology, Poland
  2. AGH University of Science and Technology, Department of Applied Computer Science and Modelling, Poland
  3. Kutno Foundry, Poland
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Abstract

A classical algorithm Tabu Search was compared with Q Learning (named learning) with regards to the scheduling problems in the Austempered Ductile Iron (ADI) manufacturing process. The first part comprised of a review of the literature concerning scheduling problems, machine learning and the ADI manufacturing process. Based on this, a simplified scheme of ADI production line was created, which a scheduling problem was described for. Moreover, a classic and training algorithm that is best suited to solve this scheduling problem was selected. In the second part, was made an implementation of chosen algorithms in Python programming language and the results were discussed. The most optimal algorithm to solve this problem was identified. In the end, all tests and their results for this project were presented.
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Bibliography

[1] Yang, L., Jiang, G., Chen, X., Li, G., Li, T. & Chen, X. (2019). Design of integrated steel production scheduling knowledge network system. Claster Comput. 10197-10206.
[2] Żurada, J. Barski, M., Jędruch, W. (1996). Artificial Neural Networks. Fundamentals of theory and application. Warszawa: PWN. (in Polish).
[3] Janiak, A. (2006). Scheduling in computer and manufacturing systems. Warszawa: Wydawnictwa Komunikacji i Łączności.
[4] Smutnicki, C. (2002). Scheduling algorithms. Warszawa: Akademicka Oficyna Wydawnicza EXIT. (in Polish).
[5] Coffman, E.G. (1980). Task scheduling theory. Warszawa: Wydawnictwa Naukowo-Techniczne. (in Polish).
[6] Janczarek, M. (2011). Managing production processes in the enterprise. Lublin: Lubelskie Towarzystwo Naukowe. (in Polish).
[7] Szeliga, M. (2019) Practical machine learning. Warszawa: PWN. (in Polish).
[8] Raschka, S. (2018) Python machine learning. Gliwice: Helion. (in Polish).
[9] Choi, H-S, Kim, J-S. & Lee, D-H. (2011). Real-time scheduling for reentrant hybrid flow shops: A decision tree based mechanism and its application to a TFT-LCD line. Expert System with Application. 38, 3514-3521.
[10] Agarwal, A., Pirkul, H. & Jacob, V.S. (2003). Augmented neutral network for task scheduling. European Journal of Operational Research. 151, 481-502.
[11] Jain, A.S. & Meeran, S. (1998). Jop-shop scheduling using neutral networks. International Journal of Production Research. 36(5), 1249-1272
[12] Fonseca-Reyna, Y.C., Martinez-Jimenez, Y. & Nowe, A. (2017). Q-Learning algorithm performance for m-machine, n-jobs flow shop scheduling problems to minimize makespan, Revista Investigacion Operacional. 38(3), 281-290.
[13] Dewi, Andriansyah, & Syahriza, (2019). Optimization of flow shop scheduling problem using classic algorithm: case study, IOP Conf. Series: Materials Science and Engineering 506.
[14] Putatunda, K. (2001) Development of austempered ductile cast iron (ADI) with simultaneous high yield strength and fracture toughness by a novel two-step austempering process. Material Science and Engineering A. 315, 70-80.
[15] Dayong Han, Hubei Key, Qiuhua Tang; Zikai Zhang; Jun Cao, (2020). Energy-efficient integration optimization of production scheduling and ladle dispatching in steelmaking plants. IEEE Access. 8, 176170-176187.
[16] Perzyk, M. (2017). The use of production data mining methods in the diagnosis of the causes of product defects and disruptions in the production process. Utrzymanie Ruchu. 4, 45-47. (in Polish).
[17] Perzyk, M., Dybowski, B. & Kozłowski, J. (2019). Introducing advanced data analytics in perspective of industry 4.0 in a die casting foundry. Archives of Foundry Engineering. 19(1), 53-57.
[18] Yescas, M. (2003). Prediction of the Vickers hardness in austempered ductile irons using neural networks. International Journal of Cast Metals Research. 15(5), 513-521.
[19] Report on the contract no. U / 227/2014 implemented at the Foundry Research Institute. (in Polish).
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Authors and Affiliations

D. Wilk-Kołodziejczyk
1 2
ORCID: ORCID
K. Chrzan
2
ORCID: ORCID
K. Jaśkowiec
2
ORCID: ORCID
Z. Pirowski
2
ORCID: ORCID
R. Żuczek
2
ORCID: ORCID
A. Bitka
2
ORCID: ORCID
D. Machulec
3
ORCID: ORCID

  1. AGH University of Science and Technology, Al. A. Mickiewicza 30, 30-059 Krakow, Poland
  2. Łukasiewicz Research Network – Krakow Institute of Technology, 73 Zakopiańska Str., 30-418 Kraków, Poland
  3. AGH University of Science and Technology, Kraków, Poland
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Abstract

The article presents the developed IT solutions supporting the material and technological conversion process in terms of the possibility of using the casting technology of selected alloys to produce products previously manufactured with the use of other methods and materials. The solutions are based on artificial intelligence, machine learning and statistical methods. The prototype module of the information and decision-making system allows for a preliminary assessment of the feasibility of this type of procedure. Currently, the selection of the method of manufacturing a product is based on the knowledge and experience of the technologist and constructor. In the described approach, this process is supported by the proprietary module of the information and decision-making system, which, based on the accumulated knowledge, allows for an initial assessment of the feasibility of a selected element in a given technology. It allows taking into account a large number of intuitive factors, as well as recording expert knowledge with the use of formal languages. Additionally, the possibility of searching for and collecting data on innovative solutions, supplying the knowledge base, should be taken into account. The developed and applied models should allow for the effective use and representation of knowledge expressed in linguistic form. In this solution, it is important to use methods that support the selection of parameters for the production of casting. The type, number and characteristics of data have an impact on the effectiveness of solutions in terms of classification and prediction of data and the relationships detected.
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Authors and Affiliations

D. Wilk-Kołodziejczyk
1 2
ORCID: ORCID
K. Jaśkowiec
2
ORCID: ORCID
A. Bitka
2
ORCID: ORCID
Z. Pirowski
2
ORCID: ORCID
M. Grudzień-Rakoczy
2
ORCID: ORCID
K. Chrzan
2
ORCID: ORCID
M. Małysza
2
ORCID: ORCID
M. Doroszewski
1
ORCID: ORCID

  1. AGH University of Science and Technology, Faculty of Metals Engineering and Industrial Computer Science, Al. Mickiewicza 30, 30-059 Kraków, Poland
  2. Centre of Casting Technology, The Łukasiewicz Research Network – Cracow Technology Institute, Poland

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