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Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI, Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI INSTITUTE FOR SUSTAINABLE TECHNOLOGIES – NATIONAL RESEARCH INSTITUTE POLAND COMPUTER-AIDED PROJECTING OF GAS NITRRIDING PROCESSES WITH UTILIZATION OF SIMULATION AND METHODS OF ARTIFICIAL INTELLIGENCE

Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI, Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI

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COMPUTER-AIDED PROJECTING OF GAS NITRRIDING PROCESSES WITH UTILIZATION OF SIMULATION AND METHODS OF ARTIFICIAL INTELLIGENCE. Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI, Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI. IN STITUTE FOR SUSTAINABLE TECHNOLOGIES – NATIONAL RESEARCH INSTITUTE POLAND. - PowerPoint PPT Presentation

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Page 1: Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI,  Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI

Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI,

Jerzy RATAJSKI, Tomasz SUSZKO,

Jerzy MICHALSKI

INSTITUTE FOR SUSTAINABLE TECHNOLOGIES – NATIONAL RESEARCH INSTITUTEPOLAND

COMPUTER-AIDED PROJECTING OF GAS NITRRIDING PROCESSES WITH UTILIZATION OF SIMULATION AND

METHODS OF ARTIFICIAL INTELLIGENCE

Page 2: Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI,  Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI

PRESENTATION PLAN

PROBLEMS TO SOLVE

METHODS OF SOLVING

EXPERT SYSTEM

MODULE DESIGN OF DYNACMICS CHARACTERISTIC OF NITIRIDING PROCESSES

MODULE OF OPTIMISATION – EVOLUTIONARY ALGORITHMS

MODULE OF DATABASES

MODULE OF NEURAL NETWORK

Page 3: Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI,  Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI

Computer-aided processes of layers creationComputer-aided processes of layers creation – How it to do ? – How it to do ?

Classical approach – empirical methods of trial and error

PROBLEMS TO SOLVE

Process milieuSubstrate material

Su

bs

tra

t m

ate

ria

l

Material with a layer

layerthickness=2.8m

Ma

teria

l with

a la

ye

r

Material selection

Selection and inspection of control parameters

Selection of the layer’s properties

Page 4: Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI,  Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI

Forecasted propertiesof a layer

Process milieuSubstrate material

Material with a layer

APPLIED MODELS

Artificial neural networks

Fuzzy logic(expert systems)

Evolutionary algorithms

Data mining models – detection of similarities

and differences in processes

Analytical models: thermodynamic, statistical,

heuristic

METHODS OF SOLVING

Archival data

Measurements on-line Measurements off-line

Input parameters Output parameters

DATABASE

Computer-aided design of layers creation

Page 5: Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI,  Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI

MODULE OF DATABASES - INFORMATION STRUCTURE

Process

Parameter nameValueParameter type

Parameter nameValueParameter type

Parameter nameValueParameter type

...

Devices MaterialsEffects of the process (economical, ecological, innovative, etc.)

Stages of the process

Parameters for the whole

process

Substrate (before the

process)

Materials with layers

(after the process)

Parameter nameValueParameter type

Parameter nameValueParameter type

Parameter nameValueParameter type

Parameter nameValueParameter type

Parameter nameValueParameter type

Device 1

Device m

Stage 1

Stage n

...

Archival process In-situ process

Page 6: Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI,  Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI

MODULE OF DATABASES - APPLICATIONLocal database

Collection of data in local databases

Operational tasks

Registration of a new process by defining process structure and saving the created structure into the databaseData modification •parameters set which describes process,•data of technological stages,•device data, •material or layer data,•dynamic characteristics of the process (or stage), •graphical data concerning results of layer structures tests,Removing data from database

Data coping

Aggregating dispersed data from local databases

Making access to data via the Internet according to users rights

Data search•SQL queries,•ranking search,•fuzzy search for data mining requirements and artificial intelligence models.

Assuring accomplishing transactions such as adding, removing, modyfing and selecting/searching data

Transaction synchronisation with the concurrent access and creation of appropriate blocades while simultaneous modyfing the same data by many usersData coherence, that is inviolability of data integrity rules

Replicationality (data repetitiveness, reverse copy)

Concurrent access for many users

Providing multi-level security systems against access to data: •setting accounts for users•setting system rights •assigning access rights to objects in database•guaranting access to tables and atributes in tables

Page 7: Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI,  Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI

EXPERT SYSTEM - STRUCTURE OF EXPERT SYSTEM

User interaction module

Selection of input and output

parameters set

Formulation of database

query

Creation of the fuzzy logic function

Knowledge bases generation

DATABASE

Database integration module

Set of processes

Inference module

Fuzzification of input parameters

values Rules congregation

Defuzzification

Optimisation module

Knowledge bases optimisation

INFERENCE RESULTS:LAYER PARAMETERS VALUES

(output parameters)

12/16

Page 8: Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI,  Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI

EXPERT SYSTEM - APPLICATION

TASKPrediction of layers properties manufacturedin nitriding and PVD processes.

Support for designing the nitriding processes

technologies on the basis of substrate

and process milieu parameters.

System propertiesInference versatility Inferencing with diverse parameters.

Flexibility and coherence of inferencing Inferencing on the basis of different

domains parameters: continue (e.g. temperature

in time function), discrete (e.g. value of layer

resistance to corrosion), nominaly ordered

(e.g. type of mechanical treatment used for substrate surface).

Inference adaptation and self-learning Using data referring to new and completed processes

as well as created layers in order to improve inference quality.

IFHTSE 2007 Congress Adam Mazurkiewicz, 31.10.200713/16

Page 9: Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI,  Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI

EXPERT SYSTEM - VALIDATION IN THE FIELD OF NITRIDING PROCESSES

Process 1 Process 2 Process 3

Process duration [min] 570 60 480

Mean nitride potential [atm½] 4.75 3.25 6

Temperature [°C] 530 570 530

Amount of N2 in the atmosphere [%] 60 20 60

Amount of NH3 in the atmosphere [%]

40 60 40

Substrate material 40 HMJ 40 HMJ 38 HMJ

Fuzzification method triangle triangle triangle

Parameter name

Process 1 Process 2 Process 3

Obtained Predicted

Obtained Predicted

Obtained Predicted

Effective thickness g400 [mµ] 0.185 0.1767 0.17 0.16210 0.2 0.1913

Effective thickness g500 [mµ] 0.09 0.086 0.07 0.06680 0.1 0.0957

Effective thickness gr+50 [mµ] 0.345 0.3295 0.24 0.22890 0.3 0.2870

Grey area thickness [mµ] 5 4.7750 4 4.18480 4.5 4.3047

Nitride layer thickness [mµ] 10 10.4500 12.5 13.0775 10.5 10.0443

Maximum hardness HV 551 575.795 538 562.8556

552 575.9568

Surface hardness HV1 659 629.345 692 723.9704

644 671.9496

Surface hardness HV10 642 670.890 630 600.8940

625 652.125

Surface hardness HV0.5 519 495.645 512 535.6544

532 555.0888

Surface hardness HV5 544 519.520 559 533.1742

562 537.6092

Process milieu and substrate

Results

10,6710,37 10,49

9,36 9,578,95

7,1 7,377,81

4,49 4,62 4,34

0

2

4

6

8

10

12

Err

or

va

lue

[%

]

22 23 24 25 26 27

Number of rules

Dependence of the error value on the number of rules in knowledge base

Process 1 Process 2 Process 3

Page 10: Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI,  Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI

MODULE DESIGN OF DYNACMICS CHARACTERISTIC OF NITIRIDING PROCESS

Purpose Designing of atmospheres for gas nitriding process.

Module properties Two- and tree-component atmospheres:

Nitriding potential model on the basis of isoconcentrative characteristics or established by the designer.

Model of dissociation level.

Designing of process environment characteristics

Page 11: Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI,  Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI

MODULE DESIGN OF DYNACMICS CHARACTERISTIC OF NITIRIDING PROCESS

temperature changes

potential changes

nitrogen concentration

profiles

concentration on phase borders

nitrides area thickness PurposeSimulation of layer growth kinetics.Simulation of nitrogen concentration profiles on phases borders.

System properties Short time of calculations.

Additional software for mathematical calculations not required.

Possibility of layer growth in time animation.

Possibility of concentrations on phase border animation.

Possibility of concentration profiles on phase border animation.

Page 12: Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI,  Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI

MODULE OF NEURAL NETWORK

Result

PurposePrediction of micro hardness distribution in the function of:Process durationTemperature Nitridning potential

Module properties Optimal structure of neuron network.

Generalization option.

Possibility of adapting for diverse materials substrates.

Page 13: Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI,  Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI

MODULE OF OPTIMISATION – EVOLUTIONARY ALGORITHMS

Result: process parameters

Purpose Temperature and nitriding potential prediction in order to obtain the projected micro hardness distribution

System properties Determining optimal average values of temperature and potential

in successive gas nitriding process.

Possibility of adapting for diverse materials substrates.

Page 14: Jerzy DOBRODZIEJ, Jacek WOJUTYŃSKI,  Jerzy RATAJSKI, Tomasz SUSZKO, Jerzy MICHALSKI

CONCLUSIONS

Modification and development of technologies, particulary working out new technological solutions.

Precise planning of processes and obtaining surface layers described by set parameters

Designed system enables:

Reduction in energy and material consumption, as a result of processes duration shortening.

The system might be used for:

Competitiveness’ enhancement of SMEs operating in surface treatment area by improving en end product quality

Designing of new properties profiles, for instance, toward development of extremely hard layers with high adhesion in aim to increase their life by surface hardness enhancement, wear resistance (pitting, micro-pitting and scuffing) and endurance of machine and tools’ elements

Creating new SMEs which are consultants in the area of surface treatment, i.e. selection of single treatment or joint treatment and their parameters for certain applications