Lalit K. Toke

Associate Professor, Production Engineering Department, Shri Guru Gobind Singhji Institute of Engineering and Technology, Vishnupuri, Nanded - 431606 (MS)

Vishal Dhore

Guru Gobind Singh College of Engineering and Research Centre, Nashik

Shubham Surwanshi

MET’s College of Engineering and Technology, Nashik

Abstract

This study focuses on casting process parameters that affect the quality of automobile products. The objective of this study is to conduct a thorough examination of the gravity flow die-casting process and to identify the sources of defects in the braking bracket component. Systematic literature and practical study of the gravity flow die-casting process to identify the process parameter for which many defects occurred in the component. The Pareto chart is to be used to find out the most common casting defects reflected in the casting process and the cause and effect (Ishikawa) diagram is to the identification of the most significant factors that causes the defect in the casting. In the braking bracket shrinkage occurred due to the high pouring temperature and short solidification time. With the presence of oxides and hydrogen gases and the inaccurate position of venting in the die, a blowhole occurred. Insufficient volume of molten metal and complex design of getting system unfilling occurred. Due to high or low die temperature and internal thermal stress concentration cracks occurred on the casting surface. In today’s competitive world, casting industries face challenges identifying defects and manufacturing defect-free castings. This industrial case study provides in-depth knowledge of casting defects and their root causes of shrinkage, blowholes, unfilling, and crack defects. This study helps to industry to improve product quality.

Keywords- casting, Ishikawa diagram, Pareto chart, pouring temperature, casting simulationimprovement