Optimization of Moulding Composition for Quality Improvement of Sand Casting
Abstract
Sand casting is a versatile and commonly used manufacturing process in the metal casting industry. This method can be used in almost all types of metal and the sand is recyclable. However, the defects in casting production such as blowholes, pinholes, shrinkage, and porosity cause imperfection in green sand moulding. The aim of this project is to optimise the composition of silica sand, bentonite, water, and coal dust in green sand to reduce the defects in the casting products using the 24-factorial experiment design method, which can produce a total of 16 runs for experiment to investigate the ratio of the four parameters. Then the experiment results of compression strength are collected and the composition effect of green sand was investigated. The results shows value of the adjusted R-square indicated that 86.92% of the total variability was explained by the model and the model predicted and actual fitted well with the experiment data. An analysis using the Design Expert software identified that bentonite and water are the main interaction effects in all of the experiments. The optimal settings for green sand composition are 95g silica sand, 24g bentonite, 8g water, and 8g coal dust. This composition has an effect of compression strength 35kN/m2.
Downloads
References
S. O. Seidu and B. J. Kutelu, ” Effects of Additives on Some Selected Properties of Base Sand,” Journal of Mineral and Material Characterization and Engineering, vol. 2, no. 5, pp. 507–512, 2014.
R. Banchhor and S. K. Ganguly, “Optimization in Green Sand casting Process for Efficient Economical and Quality Casting,” International Journal of Advanced Engineering Technology, vol. 5, pp. 25-29, 2014.
A. A. Kassie and S. B. Assfaw, “Minimization of Casting Defects,” IOSR Journal of Engineering (IOSRJEN), vol. 3, no. 5, pp. 31–38, 2013.
D. Kwaśniewska-Królikowska, and M. Holtzer, "Selection Criteria of Lustrous Carbon Carriers Properties of Lustrous Carbon", Metalurgija, vol. 52, no. 1, pp. 62–64, 2012.
C. Saikaew and S. Wiengwiset, “Applied Clay Science Optimization of Molding Sand Composition for Quality Improvement of Iron Castings”, Applied Clay Science, vol. 67, pp. 26–31, 2012.
S. Kumar, P. S. Satsangi and D. R. Prajapati, “Optimization of Green Sand Casting Process Parameters of a Foundry by using Taguchi’s Method”, International Journal of Advanced Manufacturing Technology, vol. 55, no. 1-4, pp 23-34, 2011.
P. Murguía, R. Ángel, , E. M. Villa González del Pino, Y. B. Villa and J. Hernández del Sol, “Quality improvement of a Casting Process using Design of Experiments”, Prospectiva, vol. 14, no. 1, pp. 47–53, 2016.
A. Abdullah, S. Sulaiman, B. T. Baharudin, M. K. A. Arifin and T. R. Vijayaram", Testing for Green Compression Strength and Permeability Properties on the Tailing Sand Samples Gathered from Ex Tin Mines in Perak State, Malaysia” Advanced Materials Research, vol. 445, pp. 859-864, 2014.
A. Brown, “Graded Coal-its Role in Iron Casting Production from Greensand System”, China Foundry, vol. 8, no. 2, pp. 235-238, 2011.
U. A. Dabade and R. C. Bhedasgaonkar, ”Casting Defect Analysis using Design of Experiments (DoE) and Computer Aided Casting Simulation Technique”, Procedia CIRP, vol. 7, pp. 616–621, 2013.
S. O. Seidu and B. J. Kutelu, “Effects of Additives on Some Selected Properties of Base Sand”, Journal of Minerals and Materials Characterization and Engineering, vol. 2, no. 5, pp. 507–512, Sept. 2014.
D. C. Montgomery, Design and Analysis of Experiments, 7th Edition. New York: John Wiley & Sons, 2003.
J. P. Kaushish, Manufacturing Processes, 2nd Edition. New Delhi: PHI Learning Private Limited, 2010.
Q. Jia, Y. Y. Cui, and R. Yang, “A Study of Two Refractories as Mould Materials for Investment Casting TiAl Based Alloys”, Journal of Materials Science, vol. 41, no. 10, pp. 3045-3049, 2006.
S. S. Jamkar, M. J. Desgmukh and N. A. Vidhate,”Optimization of Green Sand Casting Process Parameter by Taguchi Method: A Review“, International Journal of Mechanical Engineering, vol. 4, no. 1, 2014
R. A. Upadhye and I. P. Keswani,”Optimization of Sand Casting Process Parameter using Taguchi Method in Foundry”, International Journal of Engineering Research & Technology, vol. 1, no. 7, 2012
