Casting defect analysis using design of experiments (DoE) and computer aided casting simulation technique

Abstract

In this paper the design of experiments and computer assisted casting simulation techniques are combined to analyze the sand related and methoding related defects in green sand casting. An attempt has been made to obtain the optimal settings of the moulding sand and mould related process parameters of green sand casting process of the selected ductile iron cast component. The green sand related process parameters considered are, moisture content, green compression strength, and permeability of moulding sand and mould hardness (in horizontal direction). In first part of this paper Taguchi based L18 orthogonal array was used for the experimental purpose and analysis was carried out using Minitab software for analysis of variance (ANOVA) and analysis of mean (AOM) plot. ANOVA results indicate that the selected process parameters significantly affect the casting defects and rejection percentage. In the second part, shrinkage porosity analysis is performed using casting simulation technique by introduction of a new gating system designed, solid model developed for four cavities mould. Number of iterations using casting simulation software was performed for mould filling and solidification analysis to reduce the level and intensities of shrinkage porosities in cast component. With new gating and feeding system design reduction in shrinkage porosity (about 15%) and improvement in yield (about 5%) is observed. © 2013 The Authors.