Optimization of Sand Parameters to Improve the Quality of Cast Iron Using Taguchi

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Abstract The main aim of the foundry industries is to produce quality castings with no rejection. In addition, in the present era of global competition, manufacturing industries has bound to take the challenge that is demand for high quality product with reduced lead–time. However, with the diversity of greensand casting parameters, it results in varying effects on the quality. With sand being one of the most frequent cause of quality reject/rework, it is essential to understand the effect it has on the casting outcome. Taguchi’s approach in quality states that the quality of a product is dependent on the input, he figured that the perfect time to eliminate differences in products is during the designing and manufacturing of products, he developed a strategy for quality that can be used in process. Therefore, it is important to understand the inputs in sand mould preparation. The focus of the research is on greensand moulding process. The casting defect is the most contributing factor to quality reject in most foundries. The sand moulding process is the most contributing factor to the formation scrap. The target in foundries is to achieve low casting defects at minimum cost. It is essential to select significant parameters that cause variation of quality characteristic of castings .data should be collected dictated by the chosen orthogonal array (OA) and parameter levels. With the collected at the analysis of variance (ANOVA) can be generated to determine the statistical importance of parameter and response graphs are plotted to determine the optimum setting of control parameter

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