Open Access Open Access  Restricted Access Subscription or Fee Access

A Review on Reduction of Scrap in Foundry by Using of Quality Control Tools

Saurav Semwal, Reena Sanwal, R. S. Jadoun

Abstract


Casting is one of the oldest manufacturing processes and is a primary manufacturing process. Products originating from castings are the input for many manufacturing processes such as forging, machining, rolling, wire drawing, extrusion, and welding. Therefore, the product made from casting should be a good quality product without defects or with minimum defects. Indeed, the quality of the products reduces as a reason of many process parameters such as molten metal pouring temperatures, the moisture content in sand, skills of physical labor, the layout of the gating system, solidification of casting, the flow rate of molten metal, surrounding conditions, numerous molding sand properties and limited automation in the foundry industries. Therefore, it is very important to improve the quality of the cast product so that there is good input for the upcoming secondary process such as forging, machining, rolling, wire drawing, extrusion, and welding. This review paper describes the study of the defect in casting and many ways to improve and optimize the quality of casting by using quality control tools and simulation.

Keywords


casting, pouring temperature, moulding sand, quality control, simulation

Full Text:

PDF

References


Thoury, M., Mille, B., Séverin- Fabiani, T. et al. High spatial dynamics-photoluminescence imaging reveals the metallurgy of the earliest lost-wax cast object. Nature Communications, p. 7, 2016.

Patil Sachin S., Naik Girish R. Defect Minimization in Casting through Process Improvement-A Literature Review. IOSR Journal of Mechanical and Civil Engineering, vol. 14, no. 2 Ver. I, pp. 09–13, 2017.

V.V. Mane, Amit Sata, M.Y. Khire. New Approach to Casting Defects Classification and Analysis Supported by Simulation. 2011.

Rahul T Patil, Veena S Metri, Shubhangi S Tambore. Causes of Casting Defects with Remedies. International Journal of Engineering Research & Technology, vol. 4, no. 11, p. 6, 2015.

J.G.K. Rajesh Rajkolhe. Defects, Causes and Their Remedies in Casting Process: A Review. International Journal of Research in Advent Technology, vol. 2, no. 3, pp. 375–383, 2014.

MRPG, M.P.A. Gaikwad. Study of casting defects and their remedies. International Journal of Advance Research, pp. 523–531, 2016.

Zakir S Ansari, Imran Khan, Rehan Shaikh, Shafiuddin Syed, Asif Khan. Adoption of Quality Tools to Abate Rejection Rate in Pipe. International Journal of Recent Advancement in Engineering & Research, vol. 03, no. 05, p. 9, 2017.

P. Beeley, Foundry Technology, Hertfordshire, United Kingdom: Butterworth-Heinemann, 2001.

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 Materials Processing Technology Elsevier, p. 39–43, 2006.

N. Natarajan. K. Review Analysis of Casting Defects with Respect to Indian Standards in Cast Iron Foundry. Journal of Chemical and Pharmaceutical Sciences, no. 2, pp. 63–68, 2016.

A.J.P. Kadam. An application of pareto analysis and cause effect diagram for minimization of defects in manual casting process. International Journal of Mechanical And Production Engineering, vol. 2, no. 2, pp. 36–40, 2014.

B.J.S.J. Jadhav. Investigation and analysis of cold shut casting defect and defect reduction by using 7 quality control tools. International Journal of Advanced Engineering Research and Studies, pp. 28–30, 2013.

P.B.R. Singla. Investigation and analysis of metal casting defect by using quality control tools on

trumpet housing of a tractor: a trumpet housing of a tractor: a case study. International Journal of Scientific & Engineering Research, vol. 8, no. 12, pp. 255–263, 2017.

M.T. Team. www.mindtools.com. [Online]. Available: https://www.mindtools.com/pages/ar ticle/newTMC_03.htm.

A. Juriani. Casting Defects Analysis in Foundry and Their Remedial Measures with Industrial Case Studies. IOSR Journal of Mechanical and Civil Engineering, vol. 12, no. 6, pp. 43–54, 2015.

D.R.M. Prasan Kinagi. A Development of quality in casting by minimizing defects. International Journal of Recent Research in Civil and Mechanical Engineering, vol. 1, no. 1, pp. 31–36, 2014.

H.S.A. Kumar. Minimization of the Casting Defects Using Taguchi’s Method. International Journal of Engineering Science Invention, vol. 5, no. 12, pp. 06–10, 2016.

A. Rathore. Defects analysis and optimization of process parameters using Taguchi DoE technique for sand casting. International Research Journal of Engineering and Technology (IRJET), vol. 04, no. 08, pp. 432–437, 2017.

A. Karthik, R. Karunanithi, S.A. Srinivasan and M. Prashanth. Materials Today: Proceedings The optimization of squeeze casting process parameter for AA2219 alloy by using the Taguchi method. Materials Today: Proceedings journal, pp. 1–6, 2019.

P. Vijian and V. P. Arunachalam. Optimization of squeeze casting process parameters using Taguchi analysis. International Journal of Advanced Manufacturing Technology, vol. 33, no. 11–12, pp. 1122–1127, 2007.

K.C. Apparao and A. Kumar. Optimization of Die casting process based on Taguchi approach. Materials Today: Proceedings, vol. 4, no. 2, pp. 1852–1859, 2017.

U. Chandran R.M. Optimization of Process Parameters to Minimize the Casting Defects. International Journal of Advances in Engineering Science and Technology, vol. 3, no. 9, pp. 105–111, 2013.

M. Sengottuvelan, K. Sivakumar and M. Nandagopal. Study on Cold Metal defect in Pump Mounting Flange using Taguchi Approach. Materials Today: Proceedings, vol. 5, no. 11, pp. 25212–25218, 2018.

N.S. Saurabh Gupta. Optimization of process parameters to minimize the defects in Al-Alloy casting. International Journal For Technological Research In Engineering, vol. 2, no. 9, pp. 1774– 1777, 2015.

J. Dacombe. www.medium.com. 24 Oct 2017. [Online]. Available: https://medium.com/@jamesdacomb e/an-introduction-to-artificial-neural- networks-with-example- ad459bb6941b.

S. Hore. Neural Network Modelling to Characterize Steel Continuous Casting Process Parameters and Prediction of Casting Defects. Transactions of the Indian Institute of Metals, 2019.

J. Zheng, Q. Wang, P. Zhao and C. Wu. Optimization of high-pressure die-casting process parameters using artificial neural network. International Journal of Advanced Manufacturing Technology, vol. 44, no. 7–8, pp. 667–674, 2009.

S.J.S. Shraban Kumar Singha. Analysis and Optimization of Sand Casting Defects With the Help of

Artificial Neural Network. International Journal of Research in Engineering and Technology, vol. 04, no. 05, pp. 24–29, 2015.

V.S. Gondkar and K.H. Inamdar. Optimization of Casting Process Parameters through Simulation. International Journal of Application or Innovation in Engineering and Management, vol. 3, no. 6, pp. 276– 283, 2014.

M. Ayar, V. Ayar and P. George. Simulation and experimental validation for defect reduction in geometry varied aluminium plates casted using sand casting. Materials Today: Proceedings, p. 9, 2020.

A.A. Bhujugade and V.B. Sabnis. Analysis of Casting Defects using Casting Simulation Technique and Using Design of Experiment: A Review. International Journal for Research in Applied Science & Engineering Technology (IJRASET), vol. 3, no. Vi, pp. 786– 788, 2015.

H. Pinto and F.J. Silva. Optimisation of Die Casting Process in Zamak Alloys. Procedia Manufacturing, vol. 11, no. June, pp. 517–525, 2017. [33] P. Tao, H. Shao, Z. Ji, H. Nan and Q. Xu. Numerical simulation for the investment casting process of a large-size titanium alloy thin-wall casing. Progress in Natural Science: Materials International, vol. 28, no. 4, pp. 520–528, 2018.

P. Thakre, A.S. Chauhan, A. Satyanarayana, E. Raj Kumar and R. Pradyumna. Estimation of shrinkage & distortion in wax injection using moldex3D simulation. Materials Today: Proceedings, vol. 5, no. 9, pp. 19410–19417, 2018.

A. Walale, A. Singh Chauhan, A. Satyanarayana, G. Venkatachalam and R. Pradyumna. Analysis of shrinkage & warpage in ceramic injection molding of HPT vane leading edge core of a gas turbine casting. Materials Today: Proceedings, vol. 5, no. 9, pp. 19471–19479, 2018.

C.M. Choudhari, B.E. Narkhede and S. K. Mahajan. Casting Design and Simulation of Cover Plate using AutoCAST-X Software for Defect Minimization with Experimental Validation. Procedia Materials Science, vol. 6, pp. 786–797, 2014.

A.S. Sabau. Numerical Simulation of the Investment Casting Process. AFS Transactions, vol. 160, no. 04, pp. 1– 11, 2005.


Refbacks

  • There are currently no refbacks.