GREEN SAND MOULDING PROCESS OPTIMIZATION THROUGH TAGUCHI'S TECHNIQUE

Abstract

Now-a-days quality concept is changing towards the design phase of the product and process i.e. controlling the quality at design stage instead of controlling at the manufacturing stage. It means that product should be made right first time and every time. This is the underlying idea of off-line quality control. One of the most comprehensive and effective system of quality control is Taguchi's method which aims at achieving consistently quality of the product. The future of any casting process depends on the quality and cost of final product. Green sand moulding process is also under constant review for enhancing its efficiency with respect to the quality of the castings produced. In the present work, Taguchi parameter design has been used to determine optimal setting of process parameters that will yield optimum quality to Al-7%Si alloy castings. The sand size and size distribution, % Bentonite (clay), % moisture and pouring temperature have been selected as the process parameters. The following characteristics 'have been considered: (i) Dimensional accuracy (ii) Surface finish (iii) Volume porosity (iv) Tensile strength and Hardness The experiments were carried out by using L8(27)OA. The main effects of process parameters on the quality characteristics have been plotted. The predicted optimal values and ranges of the quality characteristics have been evaluated.