Development And Application Of Casting Defect Management And Statistics System Based On Database Construction

In order to make the category, code and name of each casting defect be same in different foundries, improve the casting defect statistics and disposal efficiency, prevent and eliminate the casting defects, give full play to the role of the new processes and technologies, eventually reduce the reject rate overall and provide adequate data for the construction of casting process database and digital and intelligent casting, the Casting Defect Management and Statistics System (CDMS) has been developed based on the casting defect database construction used to establish the standard to judge, analyze and manage the casting defects, efficiently manage the information of defect castings, do real-time, comprehensive and accurate statistics of defects, and accumulate the cases to solve the defects problems.(1) A method of classification and coding of casting defects is presented. There are more than 160 casting defects have been classified in nine categories according to their shapes, forming mechanism, damage, and so on. The nine categories respectively are A-Metallic Projections, B-Cavities, C-Crack & Cold Shut, D-Surface Defects, E-Incomplete Castings, F-Size, Shape or Weight Abnormal, G-Inclusions, H Consistence, Property or microstructure Abnormal, and I-Other Defects. Each defect is coded by a letter and three numbers. The category, code and name of each defect are kept unique by the defect standard management in the CDMS.(2) The defect standard base, quality case base, and the defect castings base have been constructed with relational database table by SQL Server 2012 on the research of the expert knowledge of defects at home and abroad, the quality cases and the defect casting disposal in Casting Division in YC DIESEL. The production base derived from the Casting Vermicular Iron Management System and the casting weight information base derived from the Casting Process Management System have been constructed through the design of the database views in YC DIESEL. And the two bases do not only provide the data needed in the defect statistics, but also avoid the repeated management of the same data.(3) The defect experience and example image has been being accumulated by using the defect standard management and the quality cases management. The mutual query model of defect standards and quality cases is greatly useful to explain the common and individual problems of casting defects.(4) Through the defect categories management, and pre-setting the responsible process, case type and security level of quality cases and the casting number, material name, defect code, defect position code, workshop, product team, responsible departments, process and disposal of defect castings, the users do not need to manually entry the common information every time when editing the defect standard, quality case, defect disposal, meanwhile, more it is helpful to keep the data normal.(5) The defect statistics has been realized by the full management of the defect, producing and disposal information of the defect castings. The statistics calculation ways are various, and the results of the defect statistics in the system include detail table and charts, such as Pareto, pie chart, histogram and line chart. The statistics are used to represent the occurrence of various defects in different production lines and castings. The defect statistics is greatly helpful to analyze and assess the production and quality of castings, find and finally solve the problems.At present, the system has been applied in several foundries in China, such as the Casting Division in YC DIESEL, Zhengzhou Research Institute of Mechanical Engineering, and so on. So far, one software copyright has been registered, and three academic papers have been published in which the ideas and methods of casting defect management and statistics are well illustrated. Last but not least, the application shows that the system is applicable for the accumulation of experience, knowledge and data of casting defects in foundries, well meeting the multi-dimension defect statistics requirement with multiple production lines, various kinds of castings, can aid the foundry workers to make the right judgment of the casting defects and solve the problems appropriately.