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Optimization of green sand casting process parameters by using Taguchi’s method

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Abstract

This paper analyses various significant process parameters of the green sand casting process. An attempt has been made to obtain optimal settings of the green sand casting process in order to yield the optimum quality characteristics of the spheroidal graphite (SG) cast iron rigid coupling castings. The process parameters considered are: green strength, moisture content, permeability and mould hardness. The effect of selected process parameters and its levels on the casting defects and the subsequent optimal settings of the parameters have been accomplished using Taguchi’s parameter design approach. The result indicates that the selected process parameters significantly affect the casting defects of SG cast iron rigid coupling castings. The estimation of the optimum performance characteristics of green sand casting at the optimum levels of parameters is done in this paper and the results are verified by confirming with practical experiments.

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Abbreviations

r :

Number of tests in a trial

y i :

Response value of observation in the ith test

DOE:

Design of experiments

ν :

Degrees of freedom

ν A :

Degrees of freedom for factor A

k A :

Number of levels for factor A

ν A*B :

Degrees of freedom for the interaction of factors A and B

ν required :

Total degrees of freedom required

ν LN :

Total degrees of freedom of the available orthogonal array

N :

Number of trials

ANOVA:

Analysis of variance

M :

Overall mean percentage defects

VFactor:

Variance of factor

SS:

Sum of square

V′:

Expected amount of variation

P:

Percent contribution

μ :

Mean

α :

Level of risk

ν e :

Degrees of freedom for the error

Ve :

Error variance

F(α, 1, ν e):

F ratio required at the level of risk

η eff :

Effective number of replications

n :

Total number of experiments

CI:

Confidence interval

T :

Average values of casting defects at different levels

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Authors and Affiliations

  1. Department of Mechanical Engineering, R.V.S. College of Engineering & Technology, Dindigul, India

    S. Guharaja & K. M. Karuppannan

  2. Department of Production Engineering, National Institute of Technology, Tiruchirappalli, 620015, India

    A. Noorul Haq

Authors
  1. S. Guharaja
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  2. A. Noorul Haq
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  3. K. M. Karuppannan
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Corresponding author

Correspondence to S. Guharaja.

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Guharaja, S., Noorul Haq, A. & Karuppannan, K.M. Optimization of green sand casting process parameters by using Taguchi’s method. Int J Adv Manuf Technol 30, 1040–1048 (2006). https://doi.org/10.1007/s00170-005-0146-2

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  • DOI: https://doi.org/10.1007/s00170-005-0146-2

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