scholarly journals Optimization of Aluminum Sand Casting process parameters on RSM and ANN methods

2021 ◽  
Author(s):  
Mahesh G ◽  
◽  
Valavan D ◽  
Baskar N ◽  
Jayasuthakar S.T. ◽  
...  
Keyword(s):  
Low Cost ◽  
Clay Content ◽  
Casting Process ◽  
Sand Casting ◽  
Raw Material ◽  
Customer Requirements ◽  
Green Sand ◽  
Casting Technique ◽  
Green Strength ◽  
Artificial Neural Network Ann

Sand casting is one of the best processes to produce a product to satisfy the customer requirements. The prime advantages of choosing the sand casting technique are perfect dimensional geometry, development of pattern is easy, production rate is high, and solidification time is low when compared to other casting techniques. The main purpose of sand casting is to produce a product with better quality in low cost. The properties of the green sand are based on the sand composition and the most important parameters in the preparation of moulding sand are green strength, moisture content and clay content. In this work, the silica oxide is blended in green sand with various compositions for cope box. The various compositions of sand parameters are experimentally investigated by using Response Surface Methodology (RSM). The results of sand parameters are compared with Artificial Neural Network (ANN) analysis. The blending of 9.2% SiO2 with green sand is very suitable for this casting process. The blending of 9.2% SiO2 with green sand is very suitable for this casting process. The effect of SiO2 blending with green sand, the initial raw material is reduced up to 25% of volume without casting defects. The hardness value increased up to 22% and the surface roughness decreased up to 12% by varying the percentage of SiO2 in green sand.

scholarly journals The Effect of Bentonite Clay on Green Compression Strength for Tailing Sands from Old Tin Mines in Perak State, Malaysia for Making Green Sand Casting Mould

2011 ◽  
Vol 471-472 ◽  
pp. 769-774 ◽  
Author(s):  
A. Abdullah ◽  
Shamsuddin Sulaiman ◽  
B.T. Hang Tuah Baharudin ◽  
Mohd Khairol A. Arifin ◽  
T.R. Vijayaram
Keyword(s):  
Compression Strength ◽  
Standard Procedure ◽  
Bentonite Clay ◽  
Clay Content ◽  
Sand Casting ◽  
Green Sand ◽  
Foundry Sand ◽  
Casting Quality ◽  
Study Test ◽  
Operating Instructions

Clay has an important role in making green sand casting mould beside water. Clay acts as binders, holding the sand grains together. Water is needed to activate the clay bond. Without the addition of water on clay, no strength would be achieved on sand mould, as the sand and clay would be just two dry materials. Bentonite clay was used in this study. Adequate clay content with suitable moisture in moulding sand is important for optimum strength and casting quality. Too little or too much clay will not give proper strength. Green compression strength is one of the mechanical properties to be considered for making green sand casting mould. The green compression strength of foundry sand is the maximum compressive strength that a mixture is capable of sustaining when prepared, rammed and tested according to standard procedure. For this study, test is conducted according to Foundry Sand Testing Equipment Operating Instructions from Ridsdale and Dietert. Result from this study indicates that tailing sand has potential for making green sand casting mould in term of green compression strength. Other factors that must be considered are permeability and shatter index.

Application of Taguchi-based Six Sigma method to reduce defects in green sand casting process: a case study

2019 ◽  
Vol 13 (2) ◽  
pp. 226
Author(s):  
Mahantesh M. Ganganallimath ◽  
Suraj Dhondiram Patil ◽  
E.V. Gijo ◽  
Roopa B. Math ◽  
Vijaykumar Hiremath
Keyword(s):  
Six Sigma ◽  
Casting Process ◽  
Sand Casting ◽  
Green Sand

scholarly journals Utilising Flowability Sensor for Green Sand Mould Characterisation

2020 ◽  
Vol 1 (1) ◽  
Author(s):  
Dheya Abdulamer ◽  
Abdulkader Kadauw ◽  
Jürgen Bast
Keyword(s):  
Compaction Pressure ◽  
Casting Process ◽  
Sand Casting ◽  
Green Sand ◽  
Optimum Parameters ◽  
Good Pattern ◽  
Sensor Signals ◽  
Sand Mould ◽  
The Cost ◽  
Non Destructive

In this work, an attempt has been made to improve the sand casting process by reducing the percentage of casting defects. The enhancement of the sand casting process is based on producing green sand castings with good pattern profiles and no failures at any complex ‎points during the separation process, handling and transportation. This work ‎introduces modified, non-destructive, direct tests for measuring sand mould ‎properties using sensor readings. ‎A new flowability sensor has been used to measure the time-dependent density, ‎distance-dependent mould hardness, and distance-dependent mould strength. The ‎sensor is able to detect sand motion at the desired points during the mould-making process. The live characterisation of the green sand mould is used to determine the optimum ‎parameters for the compaction process, reduction of the moulding time, and spent ‎energy, so that the cost of the moulding and casting process will be reduced.‎ It has been found that there is a linear relationship between the properties of the green sand samples and the sensor signals. The new method facilitates the measurement of sand properties and determines the most effective moulding parameters based on the flowability sensor readings. The resultant increases in both compactibility and compaction pressure improve mould hardness and mould strength.

scholarly journals POTENSI PASIR LOKAL TANJUNG BINTANG PADA ALUMINIUM SAND CASTING TERHADAP POROSITAS PRODUK HASIL COR ALUMINIUM

2016 ◽  
Vol 6 (1) ◽  
Author(s):  
Yusup Hendronursito ◽  
Yogi Prayanda
Keyword(s):  
Water Content ◽  
Clay Content ◽  
Sand Casting ◽  
Metal Casting ◽  
Green Sand ◽  
Aluminium Casting ◽  
Porosity Defects ◽  
Varied Level

Green sand is one of the most important components in the process of metal casting. The sand in Indonesia region is varied level of subtlety, size of sand, and shape of sand. Green sand used in the process of metal casting is possible can affect the quality of casting product. This aims to determine the potential of Tanjung Bintang sand as green sand and the quality of the product in terms of porosity defects. The research was conducted by varying sand river from Tanjung Bintang and sand from Maringgai. Composition made varying  is 100%,75%, 50%, and 25% Tanjung Bintang sand compared Maringgai sand with bentonit and water is 10% and 5% constantly .The Examine of the green sand by SNI 15-0312-1989 among other water content, clay content, Grain Finnest Number (GFN), Shape of grain. The result said aluminium casting product with  50% Tanjung Bintang sand has the lowest value of porosity, 5.08% and the higher value with 75% composition of Tanjung Bintang sand, 6.98%.

scholarly journals Effect on the Mechanical Properties of Za-27/Graphite Reinforced Composites when Routed Through a Squeeze Casting Process

2019 ◽  
Vol 8 (10) ◽  
pp. 1202-1204
Keyword(s):  
Aluminium Alloy ◽  
Squeeze Casting ◽  
Low Cost ◽  
Research Work ◽  
Roller Bearing ◽  
Casting Process ◽  
Matrix Composites ◽  
Casting Technique ◽  
Heat Expansion ◽  
Squeeze Casting Process

Zinc Aluminium Alloy with a presence of the alloy number of 27 is widely being used in the production as well as in the manufacturing of roller bearing and bushes mostly in the auto industry by replacing the bronze made bearings due to its low cost value along with the utmost best performance. And as an add-on, Zinc Aluminium Alloy 27 is a highly strengthened alloy with best metallurgical characters which is somewhat on the high side in the graph when relating it with other types of commonly utilized cast aluminium alloys. The current research work deals purely with increasing the mechanical characteristics of ZA 27 alloy and also to identify the characteristics of the similar alloy when it combines with a metal matrix composites that has been reinforced with the graphite which is purely produced by squeeze casting technique. With respect to this, the reinforced graphite and the Za 27 mixture increases the heat expansion and expands the autonomous lubrication property. The result of this research reveals about the input process parameter increase and then there will be a relevant improvement in its ductile character but with response to the rise in mass of the graphite particles, which will lead to the decrease in the mechanical property such as hardness.

Implementation of DMAIC methodology in green sand-casting process

2020 ◽  
Author(s):  
P.B. Ranade ◽  
Ganesh Reddy ◽  
Prasad Koppal ◽  
Ankit Paithankar ◽  
Shubham Shevale
Keyword(s):  
Casting Process ◽  
Sand Casting ◽  
Green Sand

scholarly journals Titanium alloy design and casting process development using an Integrated Computational Materials Engineering (ICME) approach

2020 ◽  
Vol 321 ◽  
pp. 10013
Author(s):  
Zhi Liang ◽  
Jiashi Miao ◽  
Anil K. Sachdev ◽  
James C. Williams ◽  
Alan A. Luo
Keyword(s):  
Titanium Alloy ◽  
Ceramic Coating ◽  
Process Development ◽  
Low Cost ◽  
Casting Process ◽  
Raw Material ◽  
Connecting Rod ◽  
H13 Steel ◽  
Steel Mold ◽  
Structural Applications

The application of titanium components is generally limited by their high raw material and manufacturing costs. In this paper, a lower cost cast titanium alloy based on the Ti-Al-Fe system has been designed using an ICME approach. The new alloy Ti-6Al-5Fe-0.05B-0.05C (all wt.%) significantly reduces raw material cost and demonstrates improved castability compared with the baseline Ti-6Al-4V alloy. The fine primary and secondary α phase microstructure in the new alloy, due to Fe partitioning, provides exceptionally high strength (1023 MPa yield strength and 1136 MPa ultimate tensile strength) and reasonable ductility (3.7% elongation) for structural applications. On the manufacturing front, the high cost multi-step investment casting process currently used can now be replaced with a low-cost permanent mold casting process using steel molds and a novel ceramic coating. An experimental casting setup, including an induction skull melting (ISM) system, a gravity tilt-pour system and a ceramic-coated H13 steel mold, has been used to produce near-net-shape permanent metallic mold castings with the new titanium alloy developed. Using this setup, and aided by casting process simulation, a prototype automotive connecting rod was cast successfully. The ZrO2 ceramic coating applied to the H13 steel mold was proven effective in minimizing the metal-mold reactions.

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