https://doi.org/10.26706/jpie.2.2.20211207

Abstract:

The condition of the mould cavity in sand casting is critical for foundrymen to achieve high-quality castings. Since the last few decades, optimization of green sand mixture has played a critical role in defect minimization. Experiments were carried out in this study using varying percentages (by weight) of sand additions such as water, molasses, bentonite, and fly ash. Green compression strength, permeability, compatibility, and mould hardness have all been tested as a result of the subsequent green sand mould qualities. To tackle this multi-response optimization issue, the Taguchi strategy was used, followed by Grey relational analysis (GRA). An attempt was made to achieve an ideal level of green sand combination process parameters in order to generate the best quality attributes of the green sand mould. The L18orthogonal array design by Taguchi, the Signal-to-Noise (S/N) ratio, and analysis of variance were used to evaluate the effect of chosen green sand mould process factors and their levels on the produced mould qualities. Among the other sand process factors, bentonite was determined to have the greatest effect. Through confirmation trials, a new experiment was undertaken at the ideal parametric combination to forecast and validate increase of quality features. As a result, GRA may be a complete decision-making tool for selecting the proper grade to improve the quality attributes of sand in the foundry business.

Index Terms:

Green sand mould; Molasses; Fly ash; Bentonite; Water; Orthogonal array; Grey relational analysis

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