Abstract: A casting facility control system includes: a database storing conveyance positions and mold information in association with each other; an update section updating the mold information associated with each conveyance position stored in the database; a measurement section measuring a weight of molten metal in a ladle transported to a pouring machine; a calculation section calculating the number of flasks by which the molten metal poured from the ladle can be held; a decision section recognizing, based on the number of flasks by which the poured molten metal can be held, a plurality of molds into which the molten metal to be next transported to the pouring machine is poured, adding up the planned weight of molten metal corresponding to each of the recognized molds, and determining a predicted weight of molten metal to be next transported to the pouring machine; and an output section outputting the predicted weight.

Abstract: Disclosed herein is a manufacturing line computer system including: first and second computers. The first computer includes a storage section adapted to store a template that associates role information of the second computer and a network address of the second computer; and a reply section adapted to return the network address of the second computer associated with the role information to the second computer in response to reception of the role information from the second computer. The second computer includes an input section adapted to input the role information of the second computer; a transmission section adapted to send the input role information of the second computer to the first computer; and a network address setup section adapted to specify the network address, returned from the first computer, for the second computer.

Abstract: The invention relates to a press drive for a press or a press having a press drive. The invention also relates to a method for controlling the press drive by means of a control unit. The press drive is used for moving a ram of the press in a stroke direction H between an upper return point OT and a lower return point UT. It comprises a knee lever gear having a first lever and a second lever. A connecting rod engages on the knee lever of the two levers and is connected on the other end to an eccentric of an eccentric drive. The control unit can drive the eccentric drive in a first operating mode B1 or a second operating mode B2 or, in particular, also a third operating mode B3. In the first and the second operating modes B1, B2, the eccentric oscillates in a respectively different angle region W1, W2 about a rotation axis D of the eccentric drive, thus resulting in different force and movement states of the ram in both operating modes.

Abstract: Provided is a sand mold digital flexible extrusion near-net forming optimization method based on a search algorithm. The method includes: dividing a sand mold Computer Aided Design (CAD) 3D model near-net forming region; acquiring a curved surface function of a near-net forming sand mold CAD 3D model cavity; constructing a flexible extrusion array envelope volume optimization objective function; determining a valid optimization interval R; translating the position of a sand mold CAD 3D model cavity to a search initial position; performing a global search in the valid optimization interval R, comparing flexible extrusion array envelope volume values, and saving the larger value as V(x,y)max and the corresponding position as (x,y)max; and completing the search, translating the position of the near-net forming sand mold CAD 3D model cavity to (x,y)max, and executing a flexible extrusion array shape adjusting procedure.

Abstract: A method and a device for regulating a continuous casting system. The continuous casting system has a mold (1) and a strand guide (8) which is arranged downstream of the mold (1). Molten metal (3) is cast into the mold (1), in particular via an inlet device (4). The molten metal hardens on walls (1a) of the mold (1), such that a metal strand (7) with a hardened strand shell (5) and a still liquid core (6) is formed. The metal strand (7) is drawn out of the mold (1) by mutually spaced rollers (8b) of the strand guide (8), and a measurement variable is ascertained which correlates to the undulation of the casting level formed in the mold. The measurement variable is processed using at least one computing specification and is used to reduce the undulation of the casting level. In order to reduce the undulations of the casting level, the mutual spacing of opposing rollers (8b) of the strand guide is changed cyclically prior to the full hardening point (D).

Abstract: A system and a method for automatically transporting molten metal are provided to produce a cast product with stable qualities. The system (1) for transporting molten metal from a furnace (F) to a pouring machine (100) comprises a ladle (10) for reaction, a device (50) for feeding an alloyed metal, a ladle (60) for pouring, a bogie (20) for receiving molten metal, and a bogie (70) for transporting the ladle for pouring, and a pouring machine (100). The bogie for receiving molten metal has a controller for it. The bogie for receiving molten metal has a controller for it. At least two of the controllers among the controller for the pouring machine, the controller for the device for feeding an alloyed metal, the controller for the bogie for receiving molten metal, and the controller for the bogie for transporting the ladle for pouring, are linked for the data communication.

Abstract: Disclosed herein are a system, non transitory computer-readable medium, and method for estimating database performance. A request for an estimate of data is read. The estimate is calculated based at least partially on a node located in a data structure.

Abstract: A control device of an injection apparatus outputs a control command to a hydraulic pressure device to perform injection by supplying hydraulic fluid to the back of an injection piston 15 from an accumulator 25 and, at this time, to execute speed control for controlling the speed of the plunger by an opening degree of an injection control valve. Further, the control device outputs a control command to the hydraulic pressure device to perform boosting by opening a booster valve to supply hydraulic fluid to the back of the booster piston and pressurizing the hydraulic fluid behind the injection piston by the booster piston and, at this time, to execute pressure control for controlling the pressure of the molding material by an opening degree of the injection control valve. Further, the control device can start outputting a control command for pressure control after start of outputting a control command for opening the booster valve in transition from injection to boosting.

Abstract: Provided herein is an automatic pouring method and equipment for the same that enable to inhibit the generation of residual molten metal in a ladle and thus the molten metal to be discharged therefrom can be eliminated.

Abstract: A computer executing a software algorithm may be used to detect a depression in a temperature profile. The temperature profile may be smoothed to eliminate noise. Next, the temperature profile's center may be extracted. A polynomial may be fitted to extracted data. An algorithm used to fit the polynomial may guarantee that the fitted curve's peak may be below the actual temperature data's peak. Next, residuals may be calculated by subtracting the fitted curve from the actual data. If there is a dip at the center, then the residuals in the center may be less than zero. The software algorithm executing on the computer may then make a decision based on a sign of the residuals. For example, residuals less than zero may indicate bar porosity. Residuals above zero may indicate no porosity. The magnitude of the residuals may then be used to classify a size of a detected defect.

Abstract: A batch modeling and analysis system uses a simple and computationally inexpensive technique to align data collected from an on-going, currently running or on-line batch process with a batch model formed for the batch process so as to enable the reliable determination of the current operational state of the on-line batch process with respect to the batch model. This data alignment technique enables further statistical processing techniques, such as projection to latent sources (PLS) and principle component analysis (PCA) techniques, to be applied to the on-line batch data to perform analyses on the quality of the currently running batch. These analyses, in turn, provide useful information to a user, such as a batch operator, that enables the user to determine the quality of the batch at the present time, based on the batch model, and the likelihood that the desired batch output quality metrics will be reached at the end of the batch run.

Abstract: A method of automatically pouring molten metal from a ladle into a mold by tilting the ladle. In the method, the height of molten metal located above a molten metal outlet and the weight of molten metal flowing out of the ladle are estimated using an expanded Kalman filter on the basis of: the weight of the molten metal flowing out of the ladle, said weight being measured using a load cell; the voltage inputted to a servo motor; the angle of tilt of the ladle measured by a rotary encoder; and the position of the ladle in the lifting and lowering direction thereof. The sum of the weight of the molten metal flowing out of the ladle when the ladle is tilted rearward, said weight being estimated from the angle of tilt of the ladle and the height of the molten metal located above the molten metal outlet estimated by the expanded Kalman filter, and the weight of the molten metal flowing out of the ladle estimated by the expanded Kalman filter are estimated as the final weight of outflowing molten metal.

Abstract: A system and method for directionally casting an elongated device are provided. The method includes orienting a mold within a furnace such that a first portion of the mold points downward. The first portion of the mold defines a space within the mold used to form a first end of the device. The first end of the device, when formed, has a greater mass than a second end of the device. The method also includes filling the mold with molten metal and lowering the mold out of the furnace into a liquid metal bath to immerse the first portion of the mold in the liquid metal bath. The method includes concurrently lowering the mold and the liquid metal bath to cool the molten metal.

Abstract: A mold is designed by calculating a distribution of a contact surface pressure of a mating surface of a mold under a casting condition, and setting a machining amount of the mating surface of the mold based on the calculated distribution of the contact surface pressure.

Abstract: High quality titanium ingot is produced by using recovered titanium scrap as a raw material and adding additives. Scrap, each having individual information of identification and process profile information, is passed through automatic reading means to obtain the information and to store it in a data server.

Abstract: A method and system for optimizing a simulated casting of a light weight alloy component. The simulation includes passing component design data through various computational modules relating to casting designs, process modeling and optimization, material microstructure and defects and product performance. Variations in microstructure and defects across various very small size scales are extended to increasingly larger scales to permit structural performance calculations of the cast component to take such non-uniformities into consideration. At least some of the modules employ an expert system-based approach to achieve the optimized results. The results can be compared to end user needs to determine if redesign of the part geometry or manufacturing process is needed.

Abstract: A system for controlling pouring machines, equipment for pouring molten metal using the system and a method of pouring the molten metal where the molten metal can be smoothly poured by the coordinated operation of a casting machine having a first automatic pouring machine and the second automatic pouring machine. The system for controlling the pouring machines has a main control device, a control device for controlling the first pouring machine, and a control device for controlling the second pouring machine so that the operations of two automatic pouring machines are controlled and a smooth coordinated operation of the two automatic pouring machines is realized so that the automatic pouring machines can pour the molten metal into each of a number of molds of a casting line for molds.

Abstract: Surface 27 of molten metal within a mold is constantly monitored by camera 25. Camera 25 records the surface from an obliquely upward position of the mold in an area that does not affect the casting process. Various analyzing frames such as analysis band 35, molten metal pattern 37, and injection monitoring part 43, are set with respect to the information recorded by the camera 25. The analysis band 35 includes the surface (molten metal part 31c), and is set to a predetermined width so that the direction of surface change is in the longitudinal direction. The width of the analysis band 35 is set as wide as possible in a range that does not block the discharge part (molten metal part 31a). Inside the analysis band 35, the rate of change of the binary data is calculated by the analyzing part.

Abstract: A digital processing method of a large or medium-size sand mold includes inverting a three-dimensional CAD model of a mold into a numeric controlling code, putting a prepared sand blank on a hollow grid-shaped processing platform to proceed the digital milling procedure, bringing away waste sand generated during processing by high pressure gas blown out from a nozzle near a cutter and the waste sand entering to a collecting device below the processing platform. A device for carrying out the method is disclosed. The method and the device reduce the processing steps.

Abstract: A method is provided for adjusting the inflow of liquid metal into a continuous casting mold using a closing device. The partially solidified metal strand is drawn out of the continuous casting mold. A measured actual value of the casting level is fed into a casting level controller, which derives a target setting for the closing device. The measured actual value and a target setting of the closing device are fed to an interference compensator, which determines an expected value for the casting level, which is subtracted from the measured actual value. The difference is fed to a differential controller that derives a controller output signal therefrom, which is multiplied by a superposition factor and superimposed on the target setting as an interference compensation value. An inflow signal derived from the actual setting is further superimposed on the controller output signal and fed to an integrator, which generates an output signal corresponding to the expected value for the casting level.

Abstract: A forming speed determination method for determining a forming speed of a press-processing device with a plurality of measurement points on a sheet material to conduct press-forming of the sheet material with a press-processing device at a predetermined forming speed. Strain states at respective points on the press-formed sheet material are plotted on a forming limit diagram including the forming limit curve of a sheet material to produce a strain distribution chart. Subsequently, the closest point to the forming limit curve among the points is defined as a specific measurement point. When this specific measurement point is located in the bulge region, the forming speed of a press-processing device is decreased to be slower than the above-mentioned predetermined forming speed. Meanwhile, when this specific measurement point is located in the draw region, the forming speed of a press-processing device is increased to be faster than the above-mentioned predetermined forming speed.

Abstract: The present invention is to provide a system for controlling pouring machines, equipment for pouring molten metal using the system and a method of pouring the molten metal where the molten metal can be smoothly poured by the coordinated operation of a casting machine and two automatic pouring machines, where the automatic pouring machines pours the molten metal into each of a number of molds of a casting line for mold. The first automatic pouring machine comprises a first carriage that can run in the direction of the molds of the casting line for mold and a first pouring ladle that is attached to and transported by the first carriage and the second automatic pouring machine comprises a second carriage that can run in the direction of the molds of the casting line for mold and a second pouring ladle that is attached to and transported by the second carriage.

Abstract: Computational systems, methods, and articles of manufacture to predict at least one of residual stresses and distortion in quenched aluminum castings. Residual stresses and distortion may be predicted through incorporating thermal strains induced during quenching with the nonlinear constitutive behavior of quenched microstructures of a quenched aluminum casting, wherein thermal strains arise generally from non-uniform transient temperature distribution of the casting during quenching. The transient temperature distribution of the aluminum casting during quenching may be calculated based on heat transfer coefficients specific to one or more nodes, elements and/or zones on the surfaces of the aluminum casting. The nonlinear constitutive behavior of the quenched aluminum casting may be modeled as functions of temperatures, strain rates, and microstructure variations. A material constitutive model accounts for not only strain hardening and creep, but also precipitate hardening.

Abstract: Disclosed are an inoculant feeding method and apparatus, wherein a desired amount of inoculants can be fed into a molten metal poured into a mold by an automatic molten metal pouring machine, and an automatic molten metal pouring machine using the apparatus. An inoculant feeding apparatus (1) feeds inoculants into a molten metal poured into a mold (2) from an automatic molten metal pouring machine (20), at a predetermined proportion corresponding to the amount of the poured molten metal which gradually varies. The apparatus (1) is provided with a hopper (8) which is attached to a truck (6) and which stores the inoculants, a screw conveyor (9) attached to a lower end of the hopper, a drive mechanism (10) which is attached to a base end of the screw conveyor and which drives the screw driver, and a controller (30) which controls the drive mechanism.

Abstract: A method of making steel comprising assembling a steelmaking furnace, a thin strip caster, and a mold caster, inputting to a computer data on demand for production output, raw materials, furnace availability and capacity, sequence schedules and through-put, capacities and variability, forecasting by processing by computer from the inputted data a production schedule for the steelmaking furnace, and sequence schedules for the thin strip and the mold casters as a function of molten metal availability, the thin strip and mold caster sequence schedules and through-put, and demand for production output, directing production of molten metal alternatively to the delivery systems of the thin strip caster and mold caster responsive to said forecasting, and varying during casting the rate of metal delivery through the delivery system of the thin strip caster responsive to molten metal availability and the mold caster through-put.

Abstract: If a refractory metal core (RMC) is punched, the punching asymmetry may be reflected in an asymmetry of the cast article features cast by the punched features. The punched features may have a shear zone and a fracture zone. The shear zone of the RMC will cast a relatively narrow portion of the post near one end; whereas the fracture zone will cast a relatively broader portion near the other end. The broader portion will also have a relatively shallow transition to the adjacent face of the slot-like passageway cast by the RMC. Where there is a stress asymmetry in the cast article in-use, the punching direction may be chosen so that the relatively broad portions of the post fall along the relatively higher stress face of the passageway.

Abstract: A system, method and software arrangement are provided for generating press-formed parts having a more consistent quality based on improved determination of processing conditions. For example, an apparatus can be configured to compare actual performance values of material properties provided by a material property database with standard values, and to adjust forming conditions such as a forming speed and a blank -holder pressure in accordance with the compared result. A control arrangement can be provided to control a press-forming device using the adjusted forming conditions. Accordingly, it may be possible to reduce occurrences of defects such as cracks and wrinkles when press-forming materials, and to obtain products having consistent quality and substantially identical shapes.

Abstract: The disclosed method is a control to suppress sloshing in a ladle of a pouring device and a mold caused by their movements. A plurality of flasks, each of which contains a conveyed mold, is arranged linearly between an electric pusher-cylinder and an electric cushion-cylinder. In the method, a first natural frequency of the molten metal in the ladle is calculated based on a predetermined relationship between the weight and the natural frequency for the molten metal in the ladle, and the measured weight of the molten metal in said ladle. Also, a second natural frequency of the molten metal in said mold is calculated based on a predetermined relationship between the weight and the natural frequency for the molten metal in the mold, and the measured weight of the molten metal in the mold.

Abstract: A method and computer program for the control of the heat treatment of batches of metal workpieces for increasing the degree of automation of industrial furnace plants presumes an identical batch layout, an identical treatment program, and an identical article geometry of metal workpieces and relates it to a model batch, which has been run using batch thermoelements. The model batch becomes the foundation for a new batch. Through the assumption of program parameters of the actually run process of the model batch into the program of the new batch to be run, new batch thermoelements are not required for the new batch to be run.

Abstract: An apparatus for placing solder bumps on a mold plate includes: a solder fill head configured for dispensing molten solder onto the mold plate, the solder fill head also configured for relative movement over the mold plate; and a control mechanism configured for controlling positions of the solder fill head relative to the mold plate.

Abstract: Disclosed is a curved surface forming method for a metal plate. Nonlinear finite element analysis of elasto-plastic large deformation is performed on the metal plate. The metal plate to be worked is formed so as to have a three-dimensional target curved surface on the basis of the analysis results using a plurality of forming punches connected to a hydraulic apparatus. The curved surface formation method is very useful when the metal plate is worked for small quantity batch production.

Abstract: The present invention provides a method to control automatic pouring of molten metal by a ladle that is tilted, wherein the pouring can be carried out in a way that is as close as possible to that of an experienced operator by using a computer that has programs previously installed for such purpose. The method controls a servomotor, corresponding to the desired flow pattern of the molten metal, so that the molten metal can be poured into a mold, wherein the servomotor, which tilts the ladle to pour the molten metal in the mold, is controlled by a computer that has the programs previously installed to control the pouring.

Abstract: A method of determining the impact resistance of a structure including a crushable material comprises the steps of determining for one or more layers of a finite element of said material during an impact whether said element or layer thereof is to be treated as failing by crushing. If the element or layer is determined to fail by crushing, a load-bearing portion of the structure is defined and the load-bearing portion is treated for the purpose of subsequent calculations as exhibiting an ongoing resistance.

Abstract: A castable high temperature aluminum alloy is cast by controlled solidification that combines composition design and solidification rate control to synergistically enhance the performance and versatility of the castable aluminum alloy for a wide range of elevated temperature applications. In one example, the aluminum alloy contains by weight approximately 1.0-20.0% of rare earth elements that contribute to the elevated temperature strength by forming a dispersion of insoluble particles via a eutectic microstructure. The aluminum alloy also includes approximately 0.1 to 15% by weight of minor alloy elements. Controlled solidification improves microstructural uniformity and refinement and provides the optimum structure and properties for the specific casting condition. The molten aluminum alloy is poured into an investment casing shell and lowered into a quenchant at a controlled rate.

Abstract: Disclosed are a method, system and apparatus for analyzing foam decomposition in contact mode during mold filling in lost foam casting, the foam decomposition having a foam material vapor fraction and the mold filling having a mold filling speed. The method includes providing a plurality of parameter values for casting process parameters as variables of a plurality of predetermined equations, simultaneously solving the plurality of predetermined equations including the parameter values, calculating a vapor value for the fraction of the foam material that decomposes to vapor, an undercut length value designating the amount of coating exposed to gas diffusion, and a speed value for the mold filling speed, and determining whether to adjust at least one of the parameter values based on the results for the vapor value, the undercut length value, or the speed value.

Abstract: An object of the present invention is to provide a three-dimensional CAD-system for adding data about a drafting direction of a die to three-dimensional data about the part to be formed by that die, and a cost calculation system for calculating the cost of the part based on that drafting direction data. A three-dimensional model generation unit of a CAD system generates: a three-dimensional shaped model of a given part based on information coming from an input operation unit. A drafting direction data setting unit establishes drafting direction data when the input operation unit is operated to designate the drafting direction of the die for press molding, injection molding or the like of the part in question. A projected area calculation unit calculates a projected area S of the part on a plane perpendicular to the drafting direction of the applicable die on the basis of the three-dimensional model of that part and the drafting direction data involved.

Abstract: An apparatus for placing solder bumps on a mold plate includes: a solder fill head configured for dispensing molten solder onto the mold plate, the solder fill head also configured for relative movement over the mold plate; and a control mechanism configured for controlling positions of the solder fill head relative to the mold plate.

Abstract: Disclosed is a process having an operation. The operation includes near-liquidus rheomolding of a molten light-metal alloy being injectable, under pressure, into a mold.

Abstract: A wires laid at a predetermined bend, a bend protection member, an atmosphere temperature and the initial shape and the final bent shape of the wires and the bend protection member are designated, and infinite element models are prepared for the wires and the bend protection member. Then, stresses caused during the bending and the movement from the initial shapes to the final bent shapes are calculated for the individual infinite elements, and the maximum stresses imposed on the wires and the bend protection member are searched for among the stresses that are obtained. Then, the number of bendings for endurance, in consonance with necessary prediction functions, are obtained and the maximum stresses imposed on the wires and the bend protection member. By referring to the number of bendings for endurance, the smallest number of bendings for endurance is acquired and output.

Abstract: A computer program product for controlling an apparatus for continuous casting of metals. The computer program product includes a computer readable medium and computer program instructions recorded on the computer readable medium executable by a processor for performing the steps of supplying a molten metal to a casting mold with an elongated horizontal cross section, applying at least one magnetic field to the to exert an influence on the movement of the molten metal, generating a stationary magnetic field with a variable strength across the elongated cross section of the casting mold in the vicinity of, or below, where the molten metal is supplied, and generating a variable magnetic field in an area of the upper surface of molten metal in a region that is centrally located with respect to the elongated cross section and in the vicinity of where the molten metal is supplied.

Abstract: An automated method optimally designs plates to satisfy an order book at a steel plant so as to maximize the yield of the plates designed while using capacity fully to reduce the production of surplus slabs or plates, and satisfy order deadlines. Our method consists of four main components: (1) mother plate design, (2) slab design, (3) cast design, and (4) material allocation. A column generation framework for mother plate design is used where the problem is decomposed into a master problem and a subproblem. The master problem is used to evaluate packing patterns that should be used to fulfill the order book and the subproblem generates potential one-dimensional and two-dimensional feasible packing patterns as candidates to be evaluated by the master problem. The solution to the master problem produces a list of mother plates that need to be produced. These mother plates are transformed into candidate slabs, which are represented via an interval graph.

Abstract: A reconfigurable variable blank-holder force system (and method) for producing sheet metal stampings comprises a portable hydraulic unit, controlled by a digital control system and a knowledge-based expert system to enable reconfigurability and an easy transition from the try-out stage to production. The knowledge-base has a hierarchical structure and includes stored information about part geometry, material properties and press parameters. The expert system enables an operator to determine optimal blank-holder forces, and to fine-tune through a graphical interface unit. The optimal blank-holder forces are generated by hydraulic force actuators, using a controller running a nonlinear algorithm that accounts for valve nonlinearities, variable flow-rate and numbers of operational cylinders. The portable hydraulic unit preferably comprises hydraulic cylinders with quick disconnect hoses, a manifold, servo-valves and a pump unit.

Abstract: This invention discloses a method for calculating gripper trajectories in forming equipment. The method utilizes a computer aided design (CAD) or a computer aided engineering (CAE) computer program to calculate the appropriate location, speed, controller commands, and trajectory for each gripper used during a forming process.

Abstract: Parameters specifying properties of the materials used in the lost foam casting process are input at an input step. Numerical methods may be used to simultaneously solve a set of coupled equations relating thermal properties, flow properties, and other physical properties of the metal and foam. A profile number ? and an engulf number E may be evaluated using the values of physical quantities determined during the numerical solution step. Once values for the profile number ? and engulf number E have been determined, these values may be checked to see if they lie within appropriate ranges.

Abstract: Disclosed are a method, system and apparatus for analyzing foam decomposition in gap mode during mold filling in lost foam casting, the casting process in gap mode characterized by a bubble flux and the mold filling having a mold filling speed. The method includes providing a plurality of values for casting process parameters as variables in a plurality of predetermined equations, simultaneously solving the plurality of predetermined equations including the parameter values, calculating a flux value for the bubble flux, a gap value for the gap width, and a speed value for the mold filling speed, and determining whether to adjust at least one of the parameter values based on at least one result for the bubble flux, mold filling speed, or gap width.

Abstract: In a method and apparatus for predicting process results of objects being processed in a processing chamber of a processing apparatus, operation data and process result data obtained at the time of processing each of the objects are collected and a multivariate analysis is performed on the basis of the collected operation data and process result data to obtain a first correlation therebetween. Process results are predicted on the basis of the first correlation. Weighting coefficients for the respective operation data are set on the basis of the predicted process results. A second correlation between the weighted operation data and the process result data is obtained by a multivariate analysis. Process results are predicted by using operation data, obtained when objects other than the objects used to obtain the second correlation are processed, on the basis of the second correlation.

Abstract: Steel making is a batch production process in which batches of 250 tons, called charges or heats, are grouped together in a single production run, called a cast. Because of fixed costs and downtime associated with cleanup and setup between casts, a cast of less than three charges is likely to be inefficient. As a result, short-run orders (such as, for example, orders of less than 750 tons) may present efficiency problems. The present invention transforms the operation from a make-to-order model to a make-to-stock model, enabling orders to be clustered based on considerations such as grade and geometry to maximize the number of clusters that satisfy the cast-size constraint.

Abstract: A method for modifying a stamping die to compensate for springback includes the steps of stamping a first part using a base, or pre-existing die set, and creating a surrogate die having the shape of the first stamped part. These steps are followed by simulated stamping of a blank with the surrogate die, where the blank is shaped according to the desired finished part. Then, the base die is modified by mapping the forming stresses, from the stamped blank, to an indicator blank, which is allowed to relax and then is employed as a template for modification of the base die. Following this, the accuracy of the newly modified base die is determined by stamping a second part in the modified base die and by comparing a number of dimensions of the second part with a number of corresponding dimensions of the desired finished part.

Abstract: A numerical procedure for simulating the behavior of incompressible, viscous fluid in a casting/molding process. The method is based on classical fluid dynamic equations and uses control volume-finite element and numerical techniques to solve the momentum and energy equations to obtain solution for the variable parameters. The method incorporates five additional modules which simulate fluid flow in the shot sleeve, heat transfer between the die and the heat transfer fluid, die cooling by lubricant, formation of mend line. These additional simulation modules produce realistic boundary conditions, and replace many of the assumptions that would have to be made, to solve the governing equations. These added improvements ensure a faster convergence of the numerical solution and a more realistic simulation of the die casting process.

Abstract: A real-time system and method for online monitoring a transient operation in a continuous casting process. The transient operation refers to, but is not limited to, submerged entry nozzle changes, flying tundish changes, product grade changes, etc. This invention treats the aforementioned transient operations as batch processes and utilizes multiway principal component analysis to develop a multivariate statistical model to characterize normal process transitions based on carefully selected historical process data. Such a model is used by an online monitoring system to determine if a continuous caster transient operation is normal. This monitoring system can further be used to predict an impending breakout, one type of catastrophic process failures which may occur in a continuous casting process, during the transient operation.