Title: Optimisation and predictive modelling of green sand casting process to minimise persisting defects in GI components

Authors: Sanjay N. Aloni; Sharad S. Chaudhari; Rakesh L. Shrivastava

Addresses: Department of Mechanical Engineering, Datta Meghe Institute of Engineering, Technology and Research, Salod (Hirapur), Wardha, Maharashtra-442001, India ' Department of Mechanical Engineering, Yeshwantrao Chavan College of Engineering, Hingna Road, Wanadongri, Nagpur, Maharashtra-441110, India ' Department of Mechanical Engineering, Yeshwantrao Chavan College of Engineering, Hingna Road, Wanadongri, Nagpur, Maharashtra-441110, India

Abstract: Quality of castings produced by a sand casting process have always been the result of proper control over an enormous number of parameters involved in the process, while some of the defects are persisting. In the work presented in this paper, the primary focus is on the investigation of the essential parameters of the green sand casting process for effective understanding of most influential parameters which affects the persisting defects in gray cast iron components. The study applies the Taguchi's 'design of experiments' approach for determining the optimal level of parameters to minimise the persisting defects in the foundry industry producing cast components required in the automotive, factory situated in central India. Besides, a mathematical model has been developed using multiple regression analysis for an individual defect. The outcomes of this study assure that the approach used in this work is useful to foundry industries to minimise the casting defects.

Keywords: green sand casting process; persisting casting defects; process parameters; Taguchi orthogonal array; analysis of variance; ANOVA; modelling.

DOI: 10.1504/IJPQM.2020.108379

International Journal of Productivity and Quality Management, 2020 Vol.30 No.3, pp.394 - 427

Received: 17 Dec 2018
Accepted: 15 Apr 2019

Published online: 03 Jul 2020 *

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