Title: Optimisation of green sand casting process parameters for enhancing quality of mild steel castings

Authors: Sanjiv Kumar Tiwari; Ritesh Kumar Singh; Sharad Chandra Srivastava

Addresses: Department of Production Engineering, Birla Institute of Technology, Mesra, Ranchi, Jharkhand, 835215, India ' Department of Production Engineering, Birla Institute of Technology, Mesra, Ranchi, Jharkhand, 835215, India ' Department of Production Engineering, Birla Institute of Technology, Mesra, Ranchi, Jharkhand, 835215, India

Abstract: In this paper, an attempt has been made to obtain an optimal parameter setting of green sand casting process to enhance the quality of mild steel castings by reducing the percentage of casting defects. Taguchi method of parameter design is used to set the optimal process parameters. Minimisation of casting defects is set as quality target. Analysis of variance (ANOVA) is then performed on the signal-to-noise ratio to find the optimal parameter levels and to identify the statistical significance and contribution of each factor on the casting defects. Finally, a confirmation test is performed using the optimal parameter setting, which shows that the casting defects can be minimised, effectively, by using the method proposed in the study.

Keywords: green sand casting; casting defects; Taguchi methods; design of experiments; DOE; orthogonal array; SNR; signal-to-noise ratio; analysis of variance; ANOVA; optimisation; process parameters; mild steel castings; parameter design.

DOI: 10.1504/IJPQM.2016.074446

International Journal of Productivity and Quality Management, 2016 Vol.17 No.2, pp.127 - 141

Received: 30 Dec 2013
Accepted: 17 May 2014
Published online: 31 Jan 2016 *

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