Chandrakishor Chourase

M.D. Mahajan

Abstract

Defective castings present an ever-present problem to the foundry industry. This study exhibits optimization of green sand casting process parameters by using Design of Experiment (DoE) method. Design of Experiment (DoE) is an offline quality assurance technique used to achieve best performance of product and processes. Green sand casting process comprises of large number of parameters that rightly varies the quality of the final product. The most substantial parameters throughout the process that are reflected in the experiments are pouring temperature, pouring time, mould hardness, moisture content and gating system. In the first phase, recognition of set of process parameters which are responsible for defects is done. Then these identified process parameters are examined using Design of Experiments approach. Signal-to-noise ratio is estimated, robust design factor values are estimated from the signal-to-noise calculation. ANOVA analysis is done for robust design factor values. In the second phase, optimized parameter values are adopted and ran practically. Through practical runs it is identified that the optimized values enhance the quality of product and minimize the reduction percentage.

Keywords- casting defects, design of experiment, green sand casting, taguchi method.