Optimization and Predictive Modeling of Green Sand Casting Process to Minimize Persisting Defects in GI Components

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.