Experimental Study of Sand Mold Process Parameters on Al-Alloy Sand Castings Using DoE

Abstract

Aluminum alloy castings are extensively used in general engineering, automobile, aerospace industries due to their excellent castability, machineability, corrosion resistance and high strength-to-weight ratio. Keeping in view the increase in demand for the use of aluminum in manufacturing of various components, aluminum foundries have to focus on producing quality castings. Sand mould casting process involves parameters like sand grain size, clay content, moisture content, permeability, green compression strength, mold hardness, number of ramming, shatter index, type of mold, etc., just to mention a few. Based on literature survey, brainstorming and experimental constraints; Grain size, Clay content, Moisture content and Number of ramming has been selected as process parameters keeping other parameters constant. Experiments were conducted as per Taguchi's L9 orthogonal array. Castings are made under the constraint of process parameters at three different levels. Results were evaluated to optimize the process parameters. The optimum levels are found to be: Grain size-55, Clay content-12%, Moisture content-13%, Number of ramming's-2. Confirmation test is conducted based on the optimum level of process parameters and result is found to be in confidence level.