Published Paper Details:

Green sand casting process is near net shape process capabilities has greater possible to achieve quality characteristics in casting products. Present competitive market demands the defect free products with lowest possible prize and prompt delivery. Casting process involves the large number of parameters of sub process and typical working environment due to which foundrymen faced the problem of high level rejection of casting components. Hence objective of the study is to identify, optimize process parameters to achieve better results of automobile component made by cast iron and investigate significant parameters to make casting process more robust. Defective castings have analyzed to identify major casting defects such as shrinkage, blow holes and shrinkage by using parato diagram. Castings rejected due to major casting defects have characterized to determine process parameters responsible causing major defects. The process parameters considered are green compressive strength, permeability, loss on ignition, carbon equivalent, volatile data in return sand, pouring temperature, A.F.S .number, mould hardness, return sand temperature, active clay, dead clay, moisture content and compatibility at two different levels and experiments were conducted using L16 orthogonal array as per the taguchi method. Thus multi objective process parameter optimization is performed using grey relation analysis to to reduce rejection levels of major casting defects. Analysis of variance was done for robust design parameter values.