Defect Reduction in Ring Blank Casting Through Design of Experiments

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.