Defect Reduction in Ring Blank Casting Through Design of Experiments

P. Kannan; K. Balasubramanian; R. Vinayagamoorthy

doi:10.15866/ireme.v9i6.7627

Defect Reduction in Ring Blank Casting Through Design of Experiments

P. Kannan^(1*), K. Balasubramanian⁽²⁾, R. Vinayagamoorthy⁽³⁾

^(*) Corresponding author

Authors' affiliations

DOI: https://doi.org/10.15866/ireme.v9i6.7627

Abstract

This research was carried out to optimize the pattern design parameters and to reduce the cold metal (CM) defect during piston ring blank casting made in high pressure green sand foundry. Design of experiments methodology was used to minimize the defect level in gating system of the pattern design. Multiple input factors are considered and controlled simultaneously to ensure that the effects on the output responses are causal and statistically significant. Metal feeding system parameters like runner diameter, choke thickness and pouring basin weight with different level were taken as input factors for this study. A full factorial design was used to design the experiment and the established variable relationships and studies on interaction effects were discussed in this study. Experimental data were statistically analyzed and optimized by using Yates method of computing factorial effects.
Copyright © 2015 Praise Worthy Prize - All rights reserved.

Keywords

Ring Blank Casting; Cold Metal Defect; Choke Thickness

Full Text:

PDF

References

A. Alagarsamy, Casting defect analysis procedure and a case history, PT Keith Millis Symposium on Ductile Iron Castings, 2003.

T. R. Vijayaram, S. Sulaiman, A. M. S. Hamouda, M. H. M. Ahmad, Foundry quality control aspects and prospects to reduce scrap rework and rejection in metal casting manufacturing industries, Journal of Material Processing Technology, Vol. 178, pp. 1–3, 2006.
http://dx.doi.org/10.1016/j.jmatprotec.2005.09.027

Rajesh Rajkolhe, J. G. Khan, Defects, causes and their remedies in casting process: A review, International Journal of Research in Advent Technology, Vol. 2, pp. 375-383, 2014.

A. A. Kassie, S. B. Assfaw, Minimsation of Casting defects, IOSR Journal of Engineering, Vol. 3, pp. 31-38, 2013.
http://dx.doi.org/10.9790/3021-03513138

S. Suresh, A. L. Moe, A. B. Abu, Defects reduction in Manufacturing of automobile piston ring using six sigma, Journal of Industrial and Intelligent Information, Vol. 3, pp. 32-28, 2015.
http://dx.doi.org/10.12720/jiii.3.1.32-38

D. C. Montgomery, Design and Analysis of Experiments, 5 ed, John Wiley and Sons, New York, 2001.
http://dx.doi.org/10.11120/msor.2001.01010015a

D. C. Montgomery, Runger, C. George, Applied Statistics and Probability for Engineers, 3 ed. John Wiley and Sons Inc., New York, 2003.
http://dx.doi.org/10.1080/03043799408928333

R. Vinayagamoorthy, N. Rajeswari, S. Karthikeyan, Investigations of damages during drilling of naturalsandwich composites, Applied Mechanics and Materials, Vol. 766-767, pp. 812-817, 2015.
http://dx.doi.org/10.4028/www.scientific.net/amm.766-767.812

R. Vinayagamoorthy, N. Rajeswari, S. Sivanarasimha, K.Balasubramanian, Fuzzy based optimization of thrust force and torque during drilling of natural hybrid composites, Applied Mechanics and Materials, Vol. 787, pp. 265-269, 2015.
http://dx.doi.org/10.4028/www.scientific.net/amm.787.265

Vinayagamoorthy, R., Rajeswari, N., Vijayshankar, S., Balasubramanian, K., Drilling performance investigations on hybrid composites by using D-optimal design, (2014) International Review of Mechanical Engineering (IREME), 8 (5), pp. 952-961.
http://dx.doi.org/10.15866/ireme.v8i5.3707

Mazhar Iqbal, Gating design criteria for sound casting, International Journal of Mechanical Engineering and Robotics Research, Vol. 2, pp. 675-694, 2014.

Angelo Tulumello, J.D. Tulumello, Yate’s method analysis of 2n factorial design of experiments using the TI-59, for n = 3, 4, 5, 6, Computers and Chemistry, Vol. 5, pp. 55-66, 1981.
http://dx.doi.org/10.1016/0097-8485(81)80008-3

R. Vinayagamoorthy, N. Rajeswari, K. Balasubramanian, Optimization studies on thrust force and torque during drilling of natural fiber reinforced sandwich composites, Jordan Journal of Mechanical and Industrial Engineering, Vol. 8, pp. 385-392, 2014.

R. Vinayagamoorthy, N. Rajeswari, Analysis of cutting forces during milling of natural fibered composites using fuzzy logic, International Journal of Composite Materials and Manufacturing, Vol. 2, pp. 15-21, 2012.

Refbacks

There are currently no refbacks.

Username
Password
Remember me