Optimization of sand-defects process parameters for reducing its defect using taguchi technique

Abstract

Abstract Foundry or casting manufacturing process is largely used in manufacturing of automobile and general-purpose machine components. Still this method is popular due to low cost, easiness in manufacturing and easy availability of input materials and resources. It involves a number of processes like sand preparation, pattern making, melting, pouring, cooling etc. Due to influence of so many factors defect arises by one factor or many factors. Still trial and error method are used by casting units to remove defects. Therefore, a more disciplined approach is required to find the root cause of problem. In this paper taguchi’s method and design of experiment is used to analyze sand and mould related defects. Standardization (optimization) attempt is done to obtain optimum values of process parameters by taguchi’s method whose experimental approach of design is robust. The parameters affecting the process are chosen as sand grain size, clay content, moisture percentage, pouring temperature, pouring time, green strength, permeability, mould hardness, number of vent holes, number of ramming etc. An orthogonal array L27 is selected which is based on taguchi. In this study a cast iron alloy (FG260) retainer used in tractor is focused.