Novel Approach to Thermal Processing Development for Precision Sand Casting Process (PSCP) of Aluminum Engine Blocks

2020 ◽  
Author(s):  
Robert Mackay ◽  
Abdallah Elsayed ◽  
Glenn Byczynski
Keyword(s):  
Thermal Processing ◽  
Casting Process ◽  
Sand Casting ◽  
Novel Approach ◽  
Engine Blocks

OPTIMISATION OF SAND CASTING PROCESS FOR IMPELLER USING TAGUCHI METHODOLOGY

2020 ◽  
Vol XVII (2) ◽  
pp. 23-33
Author(s):  
Faisal Hafeez ◽  
Salman Hussain ◽  
Wasim Ahmad ◽  
Mirza Jahanzaib
Keyword(s):  
Surface Roughness ◽  
Surface Defects ◽  
A356 Alloy ◽  
Casting Process ◽  
Sand Casting ◽  
Gate Length ◽  
Taguchi Methodology ◽  
Confirmatory Tests ◽  
Binder Ratio ◽  
Response Measures

This paper presents the study to investigate the effects of binder ratio, in-gate length and pouring height on hardness, surface roughness and casting defects of sand casting process. Taguchi methodology with L9 orthogonal array was employed to design the experimentation. Sand casting of six blade impeller using A356 alloy was performed and empirical models for all the above response measures were formulated. Confirmatory tests and analysis of variance results confirmed the accuracy of the model. Binder ratio was found to be the most significant parameter affecting casting surface defects and surface roughness. This was followed by pouring height and in-gate length.

scholarly journals Experimental and simulation analysis on multi-gate variants in sand casting process

2021 ◽  
Vol 62 ◽  
pp. 119-131
Author(s):  
I. Rajkumar ◽  
N. Rajini ◽  
A. Alavudeen ◽  
T. Ram Prabhu ◽  
S.O. Ismail ◽  
...  
Keyword(s):  
Simulation Analysis ◽  
Casting Process ◽  
Sand Casting

Thermal optimisation in the sand casting process

2001 ◽  
Vol 18 (3/4) ◽  
pp. 392-417 ◽  
Author(s):  
R.W. Lewis ◽  
M.T. Manzari ◽  
D.T. Gethin
Keyword(s):  
Casting Process ◽  
Sand Casting

scholarly journals Modelling the Mechanical Attributes (Roughness, Strength, and Hardness) of Al-alloy A356 during Sand Casting

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 598 ◽  
Author(s):  
Kashif Ishfaq ◽  
Muhammad Asad Ali ◽  
Naveed Ahmad ◽  
Sadaf Zahoor ◽  
Abdulrahman M. Al-Ahmari ◽  
...  
Keyword(s):  
Moisture Content ◽  
A356 Alloy ◽  
High Hardness ◽  
Casting Process ◽  
Sand Casting ◽  
Al Alloy ◽  
Electron Microscopic ◽  
Control Variables ◽  
Lower Velocity ◽  
Empirical Relations

Sand-casting is a well established primary process for manufacturing various parts of A356 alloy. However, the quality of the casting is adversely affected by the change in the magnitude of the control variables. For instance, a larger magnitude of pouring velocity induces a drop effect and a lower velocity increases the likelihood of cold-shut and mis-run types of defects. Similarly, a high pouring temperature causes the formation of hot tears, whereas a low temperature is a source of premature solidification. Likewise, a higher moisture content yields microcracks (due to gas shrinkages) in the casting and a lower moisture content results in the poor strength of the mold. Therefore, the appropriate selection of control variables is essential to ensure quality manufactured products. The empirical relations could provide valuable guidance in this regard. Additionally, although the casting process was optimized for A356 alloy, it was mostly done for a single response. Therefore, this paper aimed to formulate empirical relations for the contradictory responses, i.e., hardness, ultimate tensile strength and surface roughness, using the response surface methodology. The experimental results were comprehensively analyzed using statistical and scanning electron microscopic analyses. Optimized parameters were proposed and validated to achieve castings with high hardness (84.5 HB) and strength (153.5 MPa) with minimum roughness (5.8 µm).

scholarly journals Minimising Defect Formation in Sand Casting of Sheet Lead: A DoE Approach

Metals ◽  
2020 ◽  
Vol 10 (2) ◽  
pp. 252
Author(s):  
Arun Prabhakar ◽  
Michail Papanikolaou ◽  
Konstantinos Salonitis ◽  
Mark Jolly
Keyword(s):  
Process Parameters ◽  
Surface Defects ◽  
Defect Formation ◽  
Casting Process ◽  
Sand Casting ◽  
Sand Cast ◽  
Factors Affecting ◽  
Screening Experiments ◽  
Traditional Manufacturing ◽  
Lead Sheet

Sand casting of lead sheet is a traditional manufacturing process used up to the present due to the special features of sand cast sheet such as their attractive sheen. Similarly to any casting process, sand casting of lead sheet suffers from the presence of surface defects. In this study, a surface defect type, hereby referred to as ‘grooves’, has been investigated. The focus has been laid on the identification of the main factors affecting defect formation in this process. Based on a set of screening experiments performed using Scanning Electron Microscopy (SEM) as well as the existing literature, a number of factors affecting the formation of such defects was identified and their corresponding significance was estimated using the Analysis of Variance (ANOVA) technique. The obtained results suggest that the most significant factor affecting defect formation in sand casting of lead sheet is the composition of the moulding mixture. Defect formation was also proven to be dependent on the sand grain fineness, the quality of the melt and some of the interactions between the aforementioned process parameters. Finally, an optimal set of process parameters leading to the minimisation of surface defects was identified.

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