MYUNGHO KIM(M.Met.,Ph.D.)Inha University, Korea

2

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

3

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

4

A cottage industry produced agricultural tools/ornaments

Progress of Foundry Industry

5

Small size modern casting factories

Progress of Foundry Industry

6

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

8

A variety of cast items from the modern foundry industry

Progress of Foundry Industry

9

The largest cast component (weigh in excess of 320 tones) manufactured by Sheffield Forgemasters International (SFIL)

The largest cast component (2015)

10

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

11

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

13

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.

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감사합니다.