No.

Point
Taguchi method used to optimum the process.
Two trials:
1. Investigates rough fuctions regarding evers of all
control factors, then important control factors

2.

Second trial is tried for getting the best combination

using the optimum level of each control factor.

Casting defects analysis is the process of finding the root

cause of occurrence of defects in the rejection of casting
and taking necessary steps to reduce the defects and to
improve the casting yield.

I.
II.
III.
IV.

Cause-effect diagram
Design of experiments (doe)
Casting simulation
If-then rules (expert systems)
Artificial neural networks (ANN)

V.

New method of casting defects

analysis is proposed which is combination of DoE
(Taguchi method) and computer aided casting simulation
technique
Taguchi approach

Achieving high quality and low cost is parameter

design
Quality is measured by the deviation of a quality
characteristic from its target value.
In parameter design experiments, three types of
interactions are involved i.e., among design
parameters, between design parameters and noise
factors, and among noise factors.
When there are limits on the number of test runs, it
is better to include many design parameters in the
design matrix

Parameters should be controlled to improve the quality of

both casting process and product

Note

The elimination of noise factors ( Uncontrollable) is

impractical and often impossible, Taguchi method seeks to
minimize the effects of noise and to determine the optimal
level of the important controllable factors based on the
concept of robustness

Previous studies:
.

Taguchi and Wu (1979) recommends two

methods for reducing interactions among design
parameters transform data to reduce non-additivity
and change the non-additive design parameters into
variables that are additive. The change of variables
can be accomplished by making the test settings of
one design parameter depend on the test settings of
another design parameter.

Green sand casting process is one of the most versatile

processes in manufacturing because it is used for most
metals and alloys with high melting temperatures such as
iron, copper, and nickel.
Process:
Consists of pouring molten metal into a sand mold,
allowing the metal to solidify, and then breaking away the
sand mold to remove a casting product.

Basic components:
Pattern making, preparing a mold, pouring a molten metal,
cooling of mold, shakeout, fettling
Rejection :
Improper pattern, improper gating system, improper
control of sand parameters, improper molten metal
composition.
W.E. Deming's observation that 85% of the poor quality is
attribute to the manufacturing process and only 15% to the
worker

Taguchi:
Off-line strategy improvement in place of attempt to
inspect quality into a product on the production line.
I.

Poor quality can not be improved by the process of

inspection, screening and salvaging
No amount of inspection can put quality back into
the product, it is merely treats a symptom
Distinguishes three phase of off-line quality control
as system design, parameter design and tolerance
design

II.
III.

ANOVA:
ANOVA (Analysis of Variance) was developed by Sir
Ronald Fisher in the 1930s as a way to interpret the results
from agricultural experiments.

Types of defects:

Gas defect: The defect in this category can be

classified in to blow holes and open blows, air
inclusion and pin hole porosity. The defect can
appear in all regions of the casting.

Possible causes: All these defect are caused to a great

extent by the lower gas passing tendency of the mould
and/or improper design of the casting.
Remedies: Adequate provision for evacuation of air and
gas from the mold cavity. Increase of permeability of
mould and cores.

Shrinkage cavities: Shrinkage defect occurring

during the solidification of the casting

Possible causes: Volumetric contraction both in liquid and

solid state. Poor casting design. Low strength at high
temperature.
Remedies: Proper feeding of liquid metal is required .
Proper casting design.

Moulding material defects

Possible causes: Erosion of molding sand by the flowing

molten metal .Molding sand not having enough strength.
Higher pouring temperatures. Faulty mould making
procedure .
Remedies: Proper choice of molding sand and using
appropriate molding method. Choosing an appropriate type
and amount of betonies.

Pouring metal defect In this category defects are

miss run,cold shuts and slug inclusions.

Possible causes: The metal is unable to fill the mould

cavity completely. Premature interruption of pouring due to
workmans error
Remedies: Have sufficient metal in the ladle to fill the
mould Proper gating system proper use of pouring crew
and supervise pouring practice.

Metallurgical defect The defects that can be

grouped under this category are hot ears and hot
spots.

Possible causes: Poor casting design Damage to the casting

while hot due to rough handling or excessive temperature
at shakeout Chilling of the casting
Remedies: Improvement in casting design Proper
metallurgical control and chilling practices