Optimization of essential parameters in green sand process to minimize persisting casting defects using taguchi approach

The main objective of the work presented in this paper is the identification of most influential parameters of green sand casting process that is responsible for the occurrences of the defects which are persisting in complex gray iron components. The shrinkage porosity, blowholes, sand inclusion and low hardness are the defects which are persisting in cylinder head castings produced in gray iron by a green sand casting process. In pursuing for the identification of most influential parameters for respective defects, Taguchi's approach to parameter design is proposed. In the first stage of the study, 19 potential parameters associated with principal operations are selected and experiments are performed as per the plan given by the suitable Taguchi array, L36 OA. In the second stage optimal levels of the parameters are determined from the signal-to-noise ratio calculations. Analysis of variance (ANOVA) is subsequently performed to identify most influential parameters. Confirmation run of experiments is performed with optimal settings of parameters to verify the results. Outcome of confirmation experiments indicated that persisting defects in cylinder head castings produced by a green sand process are sufficiently reduced. © 2019 School of Science, IHU. All rights reserved.