Optimisation of Sand Casting Process for Impeller Using Taguchi Methodology

Abstract

This paper presents the study to investigate the effects of binder ratio, in-gate length and pouring height on hardness, surface roughness and casting defects of sand casting process. Taguchi methodology with L9 orthogonal array was employed to design the experimentation. Sand casting of six blade impeller using A356 alloy was performed and empirical models for all the above response measures were formulated. Confirmatory tests and analysis of variance results confirmed the accuracy of the model. Binder ratio was found to be the most significant parameter affecting casting surface defects and surface roughness. This was followed by pouring height and in-gate length.

Numerical Simulation of Sand Casting of Stainless Steel Pump Impeller

“…These advanced simulation techniques provide a virtual testing ground for impeller designs, minimizing the need for costly and time-consuming physical prototypes [36][37][38]. Through iterative modeling and optimization, engineers can fine-tune the casting process, resulting in high-quality impellers with improved performance and reliability that meet modern industry demands [39,40]. Continuing advancements in simulation and modeling techniques aim to further enhance the accuracy, efficiency, and versatility of sand casting simulations for impeller manufacturing.…”