Optimization of green sand casting process parameters of a foundry by using Taguchi's method

AUTHOR(S) Kumar, Sushil; Satsangi, P.; Prajapati, D. PUB. DATE July 2011 SOURCE International Journal of Advanced Manufacturing Technology;Jul2011, Vol. 55 Issue 1-4, p23 SOURCE TYPE Academic Journal DOC. TYPE Article ABSTRACT n optimization technique for process parameters of green sand casting of a cast iron differential housing cover based on the Taguchi parameter design approach is proposed in this paper. The process parameters considered are green strength, moisture content, pouring temperature, and mould hardness vertical and horizontal. An attempt has been made to obtain optimal level of the process parameters in order to yield the optimum quality characteristics of the cast iron differential housing cover castings. An orthogonal array, the signal-to-noise (S/N) ratio, and analysis of variance are used to analyze the effect of selected process parameters and their levels on the casting defects. The results indicate that the selected process parameters significantly affect the casting defects of grey cast iron differential housing cover castings. A confirmation run is used to verify the results, which indicated that this method is more efficient in determining the best casting parameters for differential housing cover.

Title: Implementing Mahalanobis-Taguchi system to improve casting quality in grey iron foundry

Author: Vivek V. Khanzode, J. Maiti

Address: Department of Industrial Engineering and Management, IIT, Kharagpur, India. ' Department of Industrial Engineering and Management, IIT, Kharagpur, India

Journal: Int. J. of Productivity and Quality Management, 2008 Vol.3, No.4, pp.444 - 456

Abstract: Selection of influencing variables for multivariate process monitoring and control is a basic requisite for effective process improvement in manufacturing. Mahalanobis Distance is a useful distance measure in multivariate space and Mahalanobis-Taguchi System is a method of pattern recognition and data classification based on Mahalanobis Distance. In this study, Mahalanobis-Taguchi System (MTS) was used to identify variables influencing product quality. This study was carried out at a grey iron foundry. Data was collected over a period of three months and a total of 11 variables were considered for the study. The results of MTS were used to decide a variable monitoring scheme. Results were validated through simulated data. Significant improvements in capability indices were observed for the important quality variables. For example, maximum percentage improvement was observed for Carbon (75%), followed by Phosphorous (65%), Hardness (53%), Silicon (51%), and Sulphur (48%). While the improvement was reasonable for Carbon % and Silicon %, the absolute values after control were still less than acceptable limit of 1.33 and demanded further investigation and control.

Keywords: foundry process control; Mahalanobis-Taguchi System; MTS; healthy observations; unhealthy observations; orthogonal array; casting quality; grey iron foundry; pattern recognition; data classification; Taguchi methods; Mahalanobis distance; product quality; quality improvement; process monitoring.

Optimization of the aluminium die casting process based on the Taguchi method
1. K S Anastasiou1 1. 1Technological Education Institute of Lamia 3rd Km PEO Lamias-Athinon, 35100 Lamia, Greece Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture July 1, 2002 vol. 216 no. 7 969-977

Abstract
Porosity in the die casting process causes costly scrap loss and limits the use of die-cast parts in critical high-strength applications. The amount of porosity is closely related to the die casting process parameters. Consequently, the mechanisms of porosity formation in relation to die casting parameters have to be studied in detail. A considerable reduction in porosity formation can be obtained by Taguchi technique implementation in the die casting process. Through simple multifactorial experiments in the foundry, controllable factors can be isolated to provide centring and variance control for a process variable. The primary objective of this paper is to investigate the effects of process parameters on porosity formation in the pressure die casting process to improve casting quality. Examples of the off-line technique used in a Greek aluminium die casting company are given for the purpose of illustrating the practicality and ease of use by industry engineers and managers.

The implementation of the Taguchi method to improve foundry scraps in hot box core production process at Ford casting plant
Ighaniyan, S., Hall, W., Long, John and Hodgson, Peter 2006, The implementation of the Taguchi method to improve foundry scraps in hot box core production process at Ford casting plant, in Science and processing of cast iron VIII: proceedings of the 8th International Symposium on Science and Processing of Cast Iron, Tsinghua University Press, Beijing, China, pp. 446-451

Asian Journal of Information Technology Year: 2004 | Volume: 3 | Issue: 3 | Page No.: 167-179 Robust Die Castings Process by Taguchi`s Method John G. Vlachogiannis and Ranjit K. Roy Abstract: This study discusses the Taguchi`s quality control technique, determining the optimum combination of design parameters of die casting process for optimisation in quality of aluminium alloy casting. Specifically the mechanisms of porosity formation and the AlSi9Cu3

aluminium alloy casting density in relation to die casting parameters have to be studied in detail. Through simple multifactor experiments in the foundry, controllable factors can be isolated to provide centring and variance control for process variables. The method is briefly explained and its application is demonstrated by the use of a die casting experiment in a foundry industry. Conclusively, the casting process is robust to uncontrollable factors (noise) selecting the optimum levels of process parameters with the target to illustrate practicality and ease of use by industry engineers and managers.

International Journal on Interactive Design and Manufacturing (IJIDeM) February 2009, Volume 3, Issue 1, pp 41-50

Parameter optimization of CO2 casting process by using Taguchi method

A. Noorul Haq, S. Guharaja, K. M. Karuppannan

Abstract
This study demonstrates optimization of CO2 casting process parameters by using Taguchis design of experiments method. The CO2 casting process involves a large number of parameters affecting the various quality features of the final product. The process parameters considered in this research work are weight of CO2 gas, mould hardness number, sand particle size, percentage of sodium silicate, sand mixing time, pouring time, pouring height, pouring temperature, and cooling time of poured metal. The effect of the selected process parameters on casting defects and subsequent setting of the parameters have been accomplished by using Taguchis parameter design approach. The result indicates that the selected process parameters significantly affect the defects of CO2 casting. The results are further conformed by conducting confirmation experiments.

International Journal for Quality Research

jezik rada: engleski

2012, vol. 6, br. 1, str. 81-97 izvorni nauni lanak Optimization of aluminium blank sand casting process by using Taguchi's robust design method (naslov ne postoji na srpskom) Nekere Liben Mekonnen, Singh Pal Ajit Department of Mechanical and Vehicle Engineering, School of Engineering and Information Technologies, Adama Science and Technology University, Adama, Ethiopia, Africa e-adresa: mekli2005@yahoo.com, singh_ajit_pal@hotmail.com

Saetak
(ne postoji na srpskom) In this paper, aluminium blank green sand (green) casting process was optimized by using Taguchi's robust design approach. An attempt was made to obtain optimal settings of two groups of aluminium blank sand casting processes. Single aluminium blank sand casting and double aluminium blanks sand casting for process robustness comparison. The casting process involves a number of parameters affecting various casting quality features of the product. In order to optimize the process seven control factors viz., grain size, clay content, moisture content, ramming, sprue size, riser size, and diameter to thickness (D/t) ratio of the blank were selected. Each factor was considered at three levels. For this study three uncontrollable (or noise) factors viz. metal flow rate, pouring temperature and humidity were identified. To capture the effect of noise factors casting yield, surface defects, and casting density for single and double castings were measured. An orthogonal array was constructed for the seven factors undertaken, and performing eighteen sets of experiments with their replicates generated the data. The signal-to-noise (S/N) ratios were calculated based on the design of experiments. The average values of S/N ratios for each factor at three levels were calculated and were plotted on the graph. Considering the maximum S/N ratios from the graph, the optimum levels of process factors for both single and double castings were obtained. A statistical analysis of variance (ANOVA) was performed to see which process parameters are statistically significant. A verification experiment was performed using the identified optimum conditions. The results have shown that single aluminium blank sand casting process is more robust than double aluminium blank sand casting process. This proved that single aluminium blank sand casting process had shown better insensitivity to noise factors. The experimental results confirmed the validity of used Taguchi robust design method for enhancing sand casting process and optimizing the sand casting parameters in aluminium blank casting process.

Abstracts : 2003
Die casting process optimization using Taguchi methods

G. P. Syrcos Journal of Materials Processing Technology v 135 p 68-74, April 2003 (6p) Abstract: This paper analyzes various significant process parameters of the die casting method of AlSi9Cu13 aluminum alloy. An attempt has been made to obtain optimal settings of the die casting parameters, in order to yield the optimum casting density of the AlSi9Cu13 aluminum alloy castings. The process parameters considered were: piston velocity (first and second stage), metal temperature, filling time and hydraulic pressure. The effects of the selected process parameters on the casting density and the subsequent optimal settings of the parameters have been accomplished using Taguchi's method. The results indicate that the selected parameters significantly affect the density of AlSi9Cu13 aluminum alloy castings.