Theory of combined imbalance for quality improvement in green sand molded castings

Abstract

Foundry is the discipline of experiments. Foundry operation consists of many interconnected, dynamic processes that are complex in nature which demand skills, techniques and caution to ensure and maintain a consistent quality of castings. Such a methodologically complex processes with numerous variables of process parameters also impose quality limitations on final castings. On account of the same, defect reduction becomes the important objective in green sand casting foundries. Foundries need process expertise to improve efficiency by reducing sand casting defects. The identification of process variables is known as process knowledge. This involves the approach to data collection, the conceptualization method, and the study to assess the various process variables associated with a defect-free casting generation. The paper presents a new perspective in the form of the Theory of Combined Imbalance of process parameters, a new dimension for understanding the defect generation mechanism in green sand molded castings.