Minimizing the sand casting defects by predicting and analyzing the process parameters

Abstract

quotMinimizing the Sand Casting Defects by Predicting and Analyzing the Process Parameters newlineSubmitted by: Parekh Priyank Vinodray newlinePhD scholar of Mechanical Engineering, newlineSchool of Engineering, R K University newlineSupervised by: Dr. Jeetendra A.Vadher newlineProfessor newlineMechanical Engineering Department, newlineGovernment Engineering College newlinePalanpur newline newlineKeywords: AFS test, Green Sand Casting Process, Taguchi method, Genetic Algorithm, ANN newline newlineBackground: Indian Foundries are facing the problem of scrap castings and more rejection due to some of the major defects like blowholes, porosity, slag inclusions and misrun. This research focuses on the identification of various casting defects, data collection of defects, critical parameters identification and optimization of identified parameters. newline newlineAim: The prime objective of the present work is to minimize the sand casting defects and prediction of defects. This work also focuses on the optimization of controllable critical process parameters using various optimization methods. newline newlineMaterials and Methods: newlineFor optimization of critical controllable process parameters various defects data are collected from the shop floor. Based on defects data Cause and Effect matrix is prepared for both green sand casting process and CO2 casting process. From the Cause and Effect matrix, various controllable factors are identified for both the processes. For green sand casting process critical process parameters are moisture, permeability, loss on ignition, compressive strength, volatile content, vent holes, pouring time, pouring temperature and mould hardness are identified and for CO2 casting process AFS, clay, pouring time, moisture and pouring temperature are identified as critical parameters. Various methods like Taguchi method, Genetic algorithm and simulated annealing are used for finding the optimum values of parameters. For the prediction of defects, ANN is used. For CO2 casting process, most of the rejections are due to sand related problems. Different types of sands like silica sand, chromite sand, Ceracota,