Optimization of green sand casting process parameters by using Taguchi’s method

2006 ◽  
Vol 30 (11-12) ◽  
pp. 1040-1048 ◽  
Author(s):  
S. Guharaja ◽  
A. Noorul Haq ◽  
K. M. Karuppannan
Keyword(s):  
Process Parameters ◽  
Casting Process ◽  
Sand Casting ◽  
Taguchi’S Method ◽  
Green Sand

Multi-objective optimization of western bentonite (Al2H2Na2O13Si4)-blended green sand casting process parameters to improve mould quality

2020 ◽  
pp. 1-10
Author(s):  
M. Nandagopal ◽  
K. Sivakumar ◽  
S. Velmurugan ◽  
R.B. Durairaj ◽  
G. Mageshwaran
Keyword(s):  
Process Parameters ◽  
Wall Thickness ◽  
Research Work ◽  
Casting Process ◽  
Rejection Rate ◽  
Sand Casting ◽  
Green Sand ◽  
Weight Percentage ◽  
Mould Wall

The quality of the mould in the green sand casting process plays a vital role in achieving good quality castings. In this research work, the mould properties permeability and hardness are focused on to improve the quality of the mould. These properties are improved by optimizing the process parameters such as degrees of ramming, mould wall thickness, and weight percentage of western bentonite using Taguchi-based grey relational analysis. The optimal level of these process parameters is experimentally validated by producing castings in a modern jobbing foundry. In the validation experiments, the moulds are produced with nominal hardness (92) and the mould wall thickness is reduced by creating cavities for storage of gases at a distance of 30 mm from the mould cavity. An interesting result found is that the nominal mould hardness and reduced wall thickness improve the quality of the mould by increasing the permeability value from 80 to 120. The improved mould quality reduces the mould-related casting rejection rate in pressure plate casting from 40% to 30%.

scholarly journals Minimising Defect Formation in Sand Casting of Sheet Lead: A DoE Approach

Metals ◽  
2020 ◽  
Vol 10 (2) ◽  
pp. 252
Author(s):  
Arun Prabhakar ◽  
Michail Papanikolaou ◽  
Konstantinos Salonitis ◽  
Mark Jolly
Keyword(s):  
Process Parameters ◽  
Surface Defects ◽  
Defect Formation ◽  
Casting Process ◽  
Sand Casting ◽  
Sand Cast ◽  
Factors Affecting ◽  
Screening Experiments ◽  
Traditional Manufacturing ◽  
Lead Sheet

Sand casting of lead sheet is a traditional manufacturing process used up to the present due to the special features of sand cast sheet such as their attractive sheen. Similarly to any casting process, sand casting of lead sheet suffers from the presence of surface defects. In this study, a surface defect type, hereby referred to as ‘grooves’, has been investigated. The focus has been laid on the identification of the main factors affecting defect formation in this process. Based on a set of screening experiments performed using Scanning Electron Microscopy (SEM) as well as the existing literature, a number of factors affecting the formation of such defects was identified and their corresponding significance was estimated using the Analysis of Variance (ANOVA) technique. The obtained results suggest that the most significant factor affecting defect formation in sand casting of lead sheet is the composition of the moulding mixture. Defect formation was also proven to be dependent on the sand grain fineness, the quality of the melt and some of the interactions between the aforementioned process parameters. Finally, an optimal set of process parameters leading to the minimisation of surface defects was identified.

Application of Taguchi-based Six Sigma method to reduce defects in green sand casting process: a case study

2019 ◽  
Vol 13 (2) ◽  
pp. 226
Author(s):  
Mahantesh M. Ganganallimath ◽  
Suraj Dhondiram Patil ◽  
E.V. Gijo ◽  
Roopa B. Math ◽  
Vijaykumar Hiremath
Keyword(s):  
Six Sigma ◽  
Casting Process ◽  
Sand Casting ◽  
Green Sand

scholarly journals Utilising Flowability Sensor for Green Sand Mould Characterisation

2020 ◽  
Vol 1 (1) ◽  
Author(s):  
Dheya Abdulamer ◽  
Abdulkader Kadauw ◽  
Jürgen Bast
Keyword(s):  
Compaction Pressure ◽  
Casting Process ◽  
Sand Casting ◽  
Green Sand ◽  
Optimum Parameters ◽  
Good Pattern ◽  
Sensor Signals ◽  
Sand Mould ◽  
The Cost ◽  
Non Destructive

In this work, an attempt has been made to improve the sand casting process by reducing the percentage of casting defects. The enhancement of the sand casting process is based on producing green sand castings with good pattern profiles and no failures at any complex ‎points during the separation process, handling and transportation. This work ‎introduces modified, non-destructive, direct tests for measuring sand mould ‎properties using sensor readings. ‎A new flowability sensor has been used to measure the time-dependent density, ‎distance-dependent mould hardness, and distance-dependent mould strength. The ‎sensor is able to detect sand motion at the desired points during the mould-making process. The live characterisation of the green sand mould is used to determine the optimum ‎parameters for the compaction process, reduction of the moulding time, and spent ‎energy, so that the cost of the moulding and casting process will be reduced.‎ It has been found that there is a linear relationship between the properties of the green sand samples and the sensor signals. The new method facilitates the measurement of sand properties and determines the most effective moulding parameters based on the flowability sensor readings. The resultant increases in both compactibility and compaction pressure improve mould hardness and mould strength.

Implementation of DMAIC methodology in green sand-casting process

2020 ◽  
Author(s):  
P.B. Ranade ◽  
Ganesh Reddy ◽  
Prasad Koppal ◽  
Ankit Paithankar ◽  
Shubham Shevale
Keyword(s):  
Casting Process ◽  
Sand Casting ◽  
Green Sand
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