A Production Planning Model for Make-to-Order Foundry Flow Shop with Capacity Constraint

Li, Xixing; Guo, Sen; Liu, Yi; Du, Baigang; Wang, Lei

doi:10.1155/2017/6315613

Cited by 7 publications

(3 citation statements)

References 62 publications

(58 reference statements)

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“…Li et al [20] studied a Production Planning Model for Make-to-Order Foundry Flow Shop with Capacity Constraint. The results shows that the proposed approach can achieve better profit rate of orders in actual foundry industry more effectively.…”

Section: Benefits Of Composite Materialsmentioning

confidence: 99%

Development of Aluminium Based Mango Seed Mangiferaindica Shell Ash (MSSA) Particulate Metal Matrix Composite

Ochuokpa

Sumaila

Adebisi

2021

IJEMM

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A composite material is a combination of two or more chemically distinct and insoluble phases; its properties and structural performance are superior to those of the constituents acting independently. MMCs are made by dispersing a reinforcing material into a metal matrix to improve their properties. They are prepared by powder metallurgy and casting, although several technical challenges exist with casting technology. Achieving a homogeneous distribution of reinforcement within the matrix is one such challenge, and this affects directly on the properties and quality of composite. In this work a composite is developed by adding Mango seed shell Ash (MSSA) particulate in Al- Si-Mg Alloy by mass ratio 5%, 10%, 15% and 20%. The composite was prepared by stir casting technique. It is proposed to use this material for production of motorcycle wheel hub which are subjected to continuous wear as the hubs are in direct contact with the brakes and rotating sprockets. The MSSA, was characterized using X- ray fluorescent (XRF). The result reveals SiO2, has the highest percentage composition followed by CaO, Al2O3, Fe2O3 and Mg2O as major phases. The presents of these hard constituent compounds suggests that the mango seed shell ash can be used as particulate reinforcement in various metal matrices since the chemical composition has similarity with the XRF analysis of Periwinkle shell ash, rice husk, fly ash, and bagasse ash currently used in metal matrix composite. Mechanical tests such as hardness test and impact test were conducted. The results revealed that increase in the percentage of MSSA progressively increased the hardness of the material from 5% wt to a maximum hardness of 43.2 HV at 15% addition of MSSA. This represents a 26.16% improvement over the unreinforced alloy. However, the impact energy progressively decreases of the material from 5%wt of MSSA and later increased to optimum energy at 15% addition of MSSA. From the results it is concluded that composite material such as Al- Si-Mg/ MSSA is one of the options as a material for production of motorcycle hub. The wear test of the composite was then carried out using Taguchi design to optimize the range of MSSA from 5% wt -15% wt., Sliding speed of 5cm/s -20cm/s, sliding distance from 50m to 200m, and the load of 2N, 4N, 6N, & 8N respectively. Analysis of the result of SN ratio for wear rate shows the optimum wear resistant value is in the combination of Load=4N, sliding speed = 10cm/s sliding distance=200m and MSSA=15 wt% These also correspond with the analysis of wear maps & wear rate presented in the diagrams of dynamic friction coefficient (COF) for Al-Si- Mg/ MSSA Composite.

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Section: Benefits Of Composite Materialsmentioning

confidence: 99%

Development of Aluminium Based Mango Seed Mangiferaindica Shell Ash (MSSA) Particulate Metal Matrix Composite

Ochuokpa

Sumaila

Adebisi

2021

IJEMM

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“…In a programmed model, these values are fed continuously, and corrections can be done during the melting operation. It becomes extremely difficult by foundry managers to combine the demand for a target quality through charge dynamics with energy and least cost operatives [20] [21]. The constraint with the induction furnace system with which the formation of oxides and decarburization through oxygen blowing is not permissible makes it very challenging for foundrymen to utilize it for alloy requiring close range compositions [22] [23] [24] [25] [26].…”

Section: Introductionmentioning

confidence: 99%

Simulation and Techno-Economic Performance of a Novel Charge Calculation and Melt Optimization Planning Model for Steel Making

Onigbajumo¹,

Seidu²

2020

JMMCE

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Process algorithm, numerical model and techno-economic assessment of charge calculation and furnace bath optimization for target alloy for induction furnace-based steelmaking is presented in this study. The developed algorithm combines the make-to-order (MTO) and charge optimization planning (COP) of the steel melting shop in the production of target steel composition. Using a system-level approach, the unit operations involved in the melting process were analyzed with the purpose of initial charge calculation, prevailing alloy charge prediction and optimizing the sequence of melt chemistry modification. The model performance was established using real-time production data from a cast iron-based foundry with a 1-and 2-ton induction furnace capacity and a medium carbon-based foundry with a 10-and 15-ton induction furnace capacity. A simulation engine (CastMELT) was developed in Java IDE with a MySQL database for continuous interaction with changing process parameters to run the model for validation. The comparison between the model prediction and production results was analyzed for charge prediction, melt modification and ferroalloy optimization and possible cost savings. The model performance for elemental charge prediction and calculation purpose with respect to the charge input (at overall scrap meltdown) gave R-squared, Standard Error, Pearson correlation and Significance value of (0.934, 0.06, 0.97, 0.0003) for Carbon prediction, (0.962, 0.06, 0.98, 0.00009) for Silicon prediction, (0.999, 0.048, 0.999, 9E−11) for Manganese Prediction, and (0.997, 0.076, 0.999, 6E−7) for Chromium prediction respectively. Correlation analysis for melt modification (after charging of ferroalloy) using the model for after-alloying spark analysis compared with the target chemistry is at 99.82%. The results validate the suitability of the developed model as a functional system of induction furnace melting for combined charge calcula-

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“…Stawowy and Duda presented a series of papers extending this model for two furnaces, two molding lines [2] and core shop planning [3]. Most recently Li et al [4] presented the production planning problem in a make-to-order foundry in which the total costs of production were being optimized. A review of classical mixed integer programming (MIP) approaches to solve the lot-sizing problem can be found in [5], while a review of various metaheuristics applied to this problem has been done in [6].…”

Section: Introductionmentioning

confidence: 99%

Iterated Local Search for Foundry Lotsizing and Scheduling Problem with Setup Costs

Stawowy

Duda

2017

Archives of Foundry Engineering

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The paper presents a novel Iterated Local Search (ILS) algorithm to solve multi-item multi-family capacitated lot-sizing problem with setup costs independent of the family sequence. The model has a direct application to real production planning in foundry industry, where the goal is to create the batches of manufactured castings and the sequence of the melted metal loads to prevent delays in delivery of goods to clients. We extended existing models by introducing minimal utilization of furnace capacity during preparing melted alloy. We developed simple and fast ILS algorithm with problem-specific operators that are responsible for the local search procedure. The computational experiments on ten instances of the problem showed that the presence of minimum furnace utilization constraint has great impact on economic and technological conditions of castings production. For all test instances the proposed heuristic is able to provide the results that are comparable to state-of-the art commercial solver.

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A Production Planning Model for Make-to-Order Foundry Flow Shop with Capacity Constraint

Cited by 7 publications

References 62 publications

Development of Aluminium Based Mango Seed Mangiferaindica Shell Ash (MSSA) Particulate Metal Matrix Composite

Development of Aluminium Based Mango Seed Mangiferaindica Shell Ash (MSSA) Particulate Metal Matrix Composite

Simulation and Techno-Economic Performance of a Novel Charge Calculation and Melt Optimization Planning Model for Steel Making

Iterated Local Search for Foundry Lotsizing and Scheduling Problem with Setup Costs

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