AN EXPERIMENTAL STUDY AND OPTIMIZATION OF THE PROCESS PARAMETERS TO REDUCE CASTING DEFECTS IN GREEN SAND CASTING PROCESS OF MS PRODUCT BY TAGUCHI METHOD

The main purpose of this paper is to reduce the casting defects by analyzing and detecting with the use of non-destructive testing methods. In most of the industries as we all are aware about the normal casting defects which are generated during the pouring of the metal. The main casting defects those are found in foundry are generally sand particle inclusions, gas bubbles, pinholes, cold shuts and other surface defects. The output of this paper is to reduce the selected process parameter like moisture content, green sand strength, sand particle dimension and hardness of mould, which affects the casting defects in the foundry. The improvement in the casting defects is found to be 42.99% during this experimental research. This research is very helpful in selecting the process parameter to optimize the casting defects as well as improves the quality of product by removing all casting flaws. KEY TERMS Chaplets, Core print, Cores, Die casting, Foundry, Green molding sand & Casting defects.