Design and Optimization of Gating System to Eradicate Scabbing Defects in Manifold Casting in Foundry Industries using L9 Taguchi Orthogonal Array in MINITAB 17.0

Abstract

This paper relates with casting defects like shrinkage, scabs and runner & riser defects which mainly occurs in manifold casting in foundry. The research on controlling the casting defects in foundry shop which comes in manifold 380 and these causes may result the reduction of quality of casting. Efforts has been made to minimize the casting defects using L₉ Taguchi’s orthogonal array approach through change in various parameters like as compression strength, moisture, permeability number and mould hardness number. These experiments are conducted on the basis of standard acceptance and experience of foundry men of casting set-up for casting of manifold 380 taken during controlling the parameters. Range of these parameters has been defined for casting process at different trials. L₉ Taguchi’s orthogonal array method in MINITAB 17 software has been used to find out the best optimum solution. These optimum solutions are applied on casting process and percentage rejection was found to be 0.96%. Also, by modulus calculations it has been made able to redesign the gate for controlling metal fluidity, turbulences in molten stage of metal which can withstand the sand permeability and strength to eliminate the scabbing defects in castings and to analyze simulation results.