Abstract:In this paper design of experiment and FMEA techniques are combined to analyze casting defects. Attempt has been made to get optimal parameter setting for defects like cold shut and blow hole. Producing defect free casting is impossible. Defect analysis is carried using FMEA tool and Pareto analysis to know potential causes of failure and their effects along with correct actions to improve quality strength and productivity. The main objective of this paper is to optimize sand casting process parameter using DOE method through Taguchi method. Taguchi based L9 orthogonal array was used for experimental purpose and analysis was carried out using Minitab software for analysis of mean (ANOM) plot. In this paper the data collected is taken from one foundry.
Keywords:Casting, FMEA, DOE, Taguchi methodology, Pareto analysis.
Prediction of output Responses in Milling of Casted Aluminum by using ANNijiert bestjournal
The important goal in the modern industries is to m anufacture the products with lower cost and with hi gh quality in short span of time. There are two main p ractical problems that engineers face in a manufacturing process. The first is to determine th e values of process parameters that will yield the desired product quality (meet technical specificati ons) and the second is to maximize manufacturing system performance using the available resources. T he increase of customer needs for quality products (more precise tolerances and better product surface roughness) have driven the metal cutting process. The main objective of this project work is to study the effect of surface roughness and Material Removal R ate in a machining of cast aluminum on CNC milling mach ine with High Speed Steel cutting tool. The feasibility of implementation of design of experime nts (DOE),and Artificial Neural network in milling process is analyzed.
EFFECT OF NOSE RADIUS ON SURFACE ROUGHNESS DURING CNC TURNING USING RESPONSE ...ijmech
The work and study presented in this paper aims to investigate the effect of nose radius on surface
roughness, in CNC turning of Aluminium (6061) in dry condition. The effect of cutting conditions (speed,
feed and depth of cut) and tool geometry (nose radius) on surface roughness were studied and analysed.
Design of Experiments (DOE) were conducted for the analysis of the influence of the turning parameter on
the surface roughness by using Response Surface Methodology (RSM) and then followed by optimization of
the results using Analysis of Variance (ANOVA) to minimize surface roughness. The nose radius was
identified as the most significant parameter. Surface roughness value decreased with increase in nose
radius.
Prediction of output Responses in Milling of Casted Aluminum by using ANNijiert bestjournal
The important goal in the modern industries is to m anufacture the products with lower cost and with hi gh quality in short span of time. There are two main p ractical problems that engineers face in a manufacturing process. The first is to determine th e values of process parameters that will yield the desired product quality (meet technical specificati ons) and the second is to maximize manufacturing system performance using the available resources. T he increase of customer needs for quality products (more precise tolerances and better product surface roughness) have driven the metal cutting process. The main objective of this project work is to study the effect of surface roughness and Material Removal R ate in a machining of cast aluminum on CNC milling mach ine with High Speed Steel cutting tool. The feasibility of implementation of design of experime nts (DOE),and Artificial Neural network in milling process is analyzed.
EFFECT OF NOSE RADIUS ON SURFACE ROUGHNESS DURING CNC TURNING USING RESPONSE ...ijmech
The work and study presented in this paper aims to investigate the effect of nose radius on surface
roughness, in CNC turning of Aluminium (6061) in dry condition. The effect of cutting conditions (speed,
feed and depth of cut) and tool geometry (nose radius) on surface roughness were studied and analysed.
Design of Experiments (DOE) were conducted for the analysis of the influence of the turning parameter on
the surface roughness by using Response Surface Methodology (RSM) and then followed by optimization of
the results using Analysis of Variance (ANOVA) to minimize surface roughness. The nose radius was
identified as the most significant parameter. Surface roughness value decreased with increase in nose
radius.
Analysis and Optimization Of Boring Process Parameters By Using Taguchi Metho...inventionjournals
International Journal of Engineering and Science Invention (IJESI) is an international journal intended for professionals and researchers in all fields of computer science and electronics. IJESI publishes research articles and reviews within the whole field Engineering Science and Technology, new teaching methods, assessment, validation and the impact of new technologies and it will continue to provide information on the latest trends and developments in this ever-expanding subject. The publications of papers are selected through double peer reviewed to ensure originality, relevance, and readability. The articles published in our journal can be accessed online.
The injection molding process itself is a complex mix of time, temperature and pressure
variables with a multitude of manufacturing defects that can occur without the right combination of
processing parameters and design components. Determining optimal initial process parameter
settings critically influences productivity, quality, and costs of production in the plastic injection
molding (PIM) industry. Up to now, most production engineers have used trial-and-error method to
determine initial settings for a number of parameters, including melt temperature, injection pressure,
injection velocity, injection time, packing pressure, packing time, cooling temperature, and cooling
time which depend on the engineers’ experience and intuition to determine initial process parameter
settings. However, the trial-and-error process is costly and time consuming.
Experimental investigation of chemical etching on en 5 steel using nitric acideSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Through-Hole Exit Characteristics in Drilling Of TI6AL4V and Quality Improvem...ijmech
The removal of macro-burrs formed after drilling has always been a difficult engineering problem, especially on different-machined materials with through holes. This paper aims at presenting an investigation into hole exit characteristics of Ti6Al4V drilled. Plastic deformation at the end of the cutting process or blanking results into the forming of burr, whose degree of impact is mostly affected by the processing parameters, especially the axial feed. Series experiments were conducted to analysis the effect of processing parameter on formed burr. The volume of burr has great effect on work-piece quality and product cost, the burr height formed easily decreases because great attention from scholars and engineers has been paid to, while the burr width size despised naturally plays a great influence on product quality and machining cost. The new de-burring tool are designed and applied in experiment, the decrease in burr width is obviously found, so the removal of burrs becomes much little than that gotten in traditional tool. The resulting indicates a promising future of de-burring in practical application Journals.
Optimization and Process Parameters of CNC End Milling For Aluminum Alloy 6082 ijiert bestjournal
he study aims at optimization of cutting parameters in CNC End milling of Aluminum Alloy 6082. CNC milling is a versatile and most widely used operation in present industry. Sur face quality affects fatigue life of components and influences various mechanical properties and has receive d serious attention for many years. In this work,experiments are conducted to analyze the surface roughnes s using various machining parameters such as Spindle speed,feed rate and depth of cut . The data was used to devel op surface roughness prediction models as a function of the machining parameters. In the present study,CNC machining centre with Cemented carbide end mill of 25mm diameter and 30� helix angle was used. A multiple regression analysis is used to correlate the relationship between the machining parameters and surface roughnes s. RS methodology was selected to optimize the surface roughness resulting minimum values of surface roughness and their r espective optimal conditions. Key words:CNC end milling,Aluminum alloy 6082,Taguchi,ANOVA
optimization of process parameters for cnc turning using taguchi methods for ...INFOGAIN PUBLICATION
Coated and uncoated tool inserts offers certain degrees of control on the desired rate of tool wear and surface roughness to an extent. This work pursues the quest for realizing the optimal values for the significant process parameters that bears an influence on the response parameters. Experiments were conducted on the samples of EN 24 alloy steel material with the help of PVD coated TiAlN insert and uncoated carbide insert. The experimental runs carried out with proper variation in the levels. Levels are selected with the help of manufacturing catalogue and by pilot experimentation and results are recorded for further analysis. For this study, 9 runs designed using L9 orthogonal array of Taguchi Design of Experiment. Surface roughness was measured using a Mitutoyo surface tester at test lab and material removal rate is calculated by mathematical equation. The data was compiled into Minitab 17 software for analysis. The relationship between the machining parameters and the response variables were analyzed using the Taguchi Method. Optimization of process parameters is carried out by Grey Relational Analysis method (GRA). GRA method is a powerful and most versatile tool which can manipulate the input data as per requirement and comes with results that can be used to have best multi-objective in respective concerns
A DEVELOPMENT OF QUALITY IN CASTING BY MINIMIZING DEFECTSpaperpublications3
Abstract:In this paper design of experiment and FMEA techniques are combined to analyze casting defects. Attempt has been made to get optimal parameter setting for defects like cold shut and blow hole. Producing defect free casting is impossible. Defect analysis is carried using FMEA tool and Pareto analysis to know potential causes of failure and their effects along with correct actions to improve quality strength and productivity. The main objective of this paper is to optimize sand casting process parameter using DOE method through Taguchi method. Taguchi based L9 orthogonal array was used for experimental purpose and analysis was carried out using Minitab software for analysis of mean (ANOM) plot. In this paper the data collected is taken from one foundry.
Minimization of the Casting Defects Using Taguchi’s Methodinventionjournals
This paper is relates with casting defects like pinholes, scabs, sand holes, slag, mould shifting, parting line defects, runner & riser defects which mainly occurs in valve casting in foundry. The research on controlling the casting defects in foundry shop which comes in various check valves -PN 10 and these causes may results the reduction of quality of casting. Here we have studied minimize the casting defects using Taguchi’s method through change in various parameters like as pouring temperature, green strength, mould hardness and permeability. These experiments were conducted based on standard acceptable and foundry men experience in this casting organization for casting check valves -PN 10 of various sizes & types Significant changes are taken during controlling the parameters. First we collected the data as casting defects from AV VALVE Pvt Ltd, Agra. Identify The major defects which are scab, cold shut and shrinkage. Complete this task we analyze the cause of this casting defects with the help of fish bone diagram. So we conclude that there are four parameters responsible for these casting defects. 1. Pouring Temperature (oC) 2. Sand Particle Size (AFS) 3.Mould Hardness Number 4. Permeability Number First we define the range of these parameters and then we perform the casting process at different trial and find that average percentage rejection is 6.25 of the casting product. Then we apply the Taguchi’s method and use of MINITAB 17 software to find out the optimum solution. These optimum solutions were applied on casting process and the calculated the percentage rejection 4.416 of the products. Thus we could improve 1.25% in casting defects.
APPLICATION OF GREY RELATIONAL ANALYSIS FOR MULTI VARIABLE OPTIMIZATION OF PR...IAEME Publication
The present work deals with a simple approach which predicts the optimum setting
of process parameters of drilling operation on Polymer Based Glass Fiber (PBGF)
composite. The process parameters selected are drill angle (DA), Drill diameter (DD),
Material Thickness (MT), Speed (N) and Feed (f). The output parameters are Thrust,
Torque, Surface Roughness and Delamination. Three levels of each input parameters
are considered. Taguchi’s L27 array is used to set the process parameters. Gray
relational analysis (GRA) is used to find the optimum value of process parameters.
Conduction of ANOVA on GRA shown the significance of each factor on the process
output. A conformation test conducted revealed that the setting of parameters ensures
optimum output
Analysis and Optimization Of Boring Process Parameters By Using Taguchi Metho...inventionjournals
International Journal of Engineering and Science Invention (IJESI) is an international journal intended for professionals and researchers in all fields of computer science and electronics. IJESI publishes research articles and reviews within the whole field Engineering Science and Technology, new teaching methods, assessment, validation and the impact of new technologies and it will continue to provide information on the latest trends and developments in this ever-expanding subject. The publications of papers are selected through double peer reviewed to ensure originality, relevance, and readability. The articles published in our journal can be accessed online.
The injection molding process itself is a complex mix of time, temperature and pressure
variables with a multitude of manufacturing defects that can occur without the right combination of
processing parameters and design components. Determining optimal initial process parameter
settings critically influences productivity, quality, and costs of production in the plastic injection
molding (PIM) industry. Up to now, most production engineers have used trial-and-error method to
determine initial settings for a number of parameters, including melt temperature, injection pressure,
injection velocity, injection time, packing pressure, packing time, cooling temperature, and cooling
time which depend on the engineers’ experience and intuition to determine initial process parameter
settings. However, the trial-and-error process is costly and time consuming.
Experimental investigation of chemical etching on en 5 steel using nitric acideSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Through-Hole Exit Characteristics in Drilling Of TI6AL4V and Quality Improvem...ijmech
The removal of macro-burrs formed after drilling has always been a difficult engineering problem, especially on different-machined materials with through holes. This paper aims at presenting an investigation into hole exit characteristics of Ti6Al4V drilled. Plastic deformation at the end of the cutting process or blanking results into the forming of burr, whose degree of impact is mostly affected by the processing parameters, especially the axial feed. Series experiments were conducted to analysis the effect of processing parameter on formed burr. The volume of burr has great effect on work-piece quality and product cost, the burr height formed easily decreases because great attention from scholars and engineers has been paid to, while the burr width size despised naturally plays a great influence on product quality and machining cost. The new de-burring tool are designed and applied in experiment, the decrease in burr width is obviously found, so the removal of burrs becomes much little than that gotten in traditional tool. The resulting indicates a promising future of de-burring in practical application Journals.
Optimization and Process Parameters of CNC End Milling For Aluminum Alloy 6082 ijiert bestjournal
he study aims at optimization of cutting parameters in CNC End milling of Aluminum Alloy 6082. CNC milling is a versatile and most widely used operation in present industry. Sur face quality affects fatigue life of components and influences various mechanical properties and has receive d serious attention for many years. In this work,experiments are conducted to analyze the surface roughnes s using various machining parameters such as Spindle speed,feed rate and depth of cut . The data was used to devel op surface roughness prediction models as a function of the machining parameters. In the present study,CNC machining centre with Cemented carbide end mill of 25mm diameter and 30� helix angle was used. A multiple regression analysis is used to correlate the relationship between the machining parameters and surface roughnes s. RS methodology was selected to optimize the surface roughness resulting minimum values of surface roughness and their r espective optimal conditions. Key words:CNC end milling,Aluminum alloy 6082,Taguchi,ANOVA
optimization of process parameters for cnc turning using taguchi methods for ...INFOGAIN PUBLICATION
Coated and uncoated tool inserts offers certain degrees of control on the desired rate of tool wear and surface roughness to an extent. This work pursues the quest for realizing the optimal values for the significant process parameters that bears an influence on the response parameters. Experiments were conducted on the samples of EN 24 alloy steel material with the help of PVD coated TiAlN insert and uncoated carbide insert. The experimental runs carried out with proper variation in the levels. Levels are selected with the help of manufacturing catalogue and by pilot experimentation and results are recorded for further analysis. For this study, 9 runs designed using L9 orthogonal array of Taguchi Design of Experiment. Surface roughness was measured using a Mitutoyo surface tester at test lab and material removal rate is calculated by mathematical equation. The data was compiled into Minitab 17 software for analysis. The relationship between the machining parameters and the response variables were analyzed using the Taguchi Method. Optimization of process parameters is carried out by Grey Relational Analysis method (GRA). GRA method is a powerful and most versatile tool which can manipulate the input data as per requirement and comes with results that can be used to have best multi-objective in respective concerns
A DEVELOPMENT OF QUALITY IN CASTING BY MINIMIZING DEFECTSpaperpublications3
Abstract:In this paper design of experiment and FMEA techniques are combined to analyze casting defects. Attempt has been made to get optimal parameter setting for defects like cold shut and blow hole. Producing defect free casting is impossible. Defect analysis is carried using FMEA tool and Pareto analysis to know potential causes of failure and their effects along with correct actions to improve quality strength and productivity. The main objective of this paper is to optimize sand casting process parameter using DOE method through Taguchi method. Taguchi based L9 orthogonal array was used for experimental purpose and analysis was carried out using Minitab software for analysis of mean (ANOM) plot. In this paper the data collected is taken from one foundry.
Minimization of the Casting Defects Using Taguchi’s Methodinventionjournals
This paper is relates with casting defects like pinholes, scabs, sand holes, slag, mould shifting, parting line defects, runner & riser defects which mainly occurs in valve casting in foundry. The research on controlling the casting defects in foundry shop which comes in various check valves -PN 10 and these causes may results the reduction of quality of casting. Here we have studied minimize the casting defects using Taguchi’s method through change in various parameters like as pouring temperature, green strength, mould hardness and permeability. These experiments were conducted based on standard acceptable and foundry men experience in this casting organization for casting check valves -PN 10 of various sizes & types Significant changes are taken during controlling the parameters. First we collected the data as casting defects from AV VALVE Pvt Ltd, Agra. Identify The major defects which are scab, cold shut and shrinkage. Complete this task we analyze the cause of this casting defects with the help of fish bone diagram. So we conclude that there are four parameters responsible for these casting defects. 1. Pouring Temperature (oC) 2. Sand Particle Size (AFS) 3.Mould Hardness Number 4. Permeability Number First we define the range of these parameters and then we perform the casting process at different trial and find that average percentage rejection is 6.25 of the casting product. Then we apply the Taguchi’s method and use of MINITAB 17 software to find out the optimum solution. These optimum solutions were applied on casting process and the calculated the percentage rejection 4.416 of the products. Thus we could improve 1.25% in casting defects.
APPLICATION OF GREY RELATIONAL ANALYSIS FOR MULTI VARIABLE OPTIMIZATION OF PR...IAEME Publication
The present work deals with a simple approach which predicts the optimum setting
of process parameters of drilling operation on Polymer Based Glass Fiber (PBGF)
composite. The process parameters selected are drill angle (DA), Drill diameter (DD),
Material Thickness (MT), Speed (N) and Feed (f). The output parameters are Thrust,
Torque, Surface Roughness and Delamination. Three levels of each input parameters
are considered. Taguchi’s L27 array is used to set the process parameters. Gray
relational analysis (GRA) is used to find the optimum value of process parameters.
Conduction of ANOVA on GRA shown the significance of each factor on the process
output. A conformation test conducted revealed that the setting of parameters ensures
optimum output
Effect of Composition of Sand Mold on Mechanical Properties and Density of Al...IJERA Editor
Sand casting process involves many parameters such as size of the sand grain, amount of clay, percentage of moisture, green compressive strength, permeability, number of ramming, shatter index, mold type, mold hardness, etc. to name a few. In this paper the effect of sand mold casting process parameters, especially composition of molding sand, on hardness, tensile strength and density of aluminium alloy castings are studied. While other parameters are kept constant, grain fineness number, amount of clay, amount of moisture and number of ramming are varied. Experiments are conducted based on Taguchi’s L9 orthogonal array and cast specimens are tested to obtain their mechanical properties and density. The results obtained are evaluated to optimize process parameters at three different levels. . Optimum levels are found as Grain fineness number 55, two times ramming, 12 percent Clay and 13 percent Moisture. Based on optimum level of process parameters, confirmation test is conducted and results are found to be in confidence level.
INFLUENCE OF PROCESS PARAMETERS ON SURFACE ROUGHNESS AND MATERIAL REMOVAL RAT...ijmech
Optimization of machining parameters is very valuable to maintain the accuracy of the components and
obtain cost effective Machining.MRR (material removal rate) and surface roughness is playing primary
role in manufacturing using contemporary CNC (computer numerical controlled) machines, in the case of
mass manufacturing. In present study experimental and work is done for optimization of process
parameters. In experimental work total 32 experiments are designed according DOE method “Mixed
taguchi”. Three factors are selected for experimental work. Depth of cut, speed and feed rate is selected
factors for experimental work. All experiments are carried out in CIPET, Jaipur. Two responses are find
out in this work and are following: first one is material removal rate (MRR) and second response is surface
roughness (Ra) measurement. An artificial neural network is ‘Feed Forward Back Propagation’ type
model of developing the analysis and prediction of surface roughness and MRR with relationship between
all input process parameters
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
EFFECT OF PROCESS PARAMETERS ON FLATNESS OF PLASTIC COMPONENT IAEME Publication
Dimensional changes because of shrinkage is one of the most important problem in production of plastic parts using plastic injection molding(PIM). In this study, effect of injection
molding parameters on surface flatness of plastic component is investigated and achieving the flatness according to customer requirement is the big task, for that this work is carried out.
Experimental Study of Surface Parameters of EN31 on Powder Mixed EDM using Ta...ijsrd.com
PEDM has become an effective method of machining extremely tough and brittle electrically conductive materials. It is widely used in the process of making moulds and dies and sections of complex geometry and intricate shapes. The work piece material selected in this experiment is EN 31 taking into account its wide usage in industrial applications. In today’s world 304 stainless steel contributes to almost half of the world’s production and consumption for industrial purposes. The input variable parameters are type of powder, current, pulse on time and powder concentration. Taguchi method is applied to create an L18 orthogonal array of input variables using the Design of Experiments (DOE). The effect of the variable parameters mentioned above upon machining characteristics such as Material Removal Rate (MRR) and Surface Roughness (SR) is studied and investigated. The tool material is copper. All the calculations are made with the help of MINITAB 16 software. Dielectric used for experimentation is kerosene. Two powders silicon carbide and boron carbide of 70 mesh is used. Most influence factor for MRR observed is powder concentration with 49.12 % contribution. For SR peak current with contribution of 43.4 % plays a n important role.
Analysis of Process Parameters for Optimization of Plastic Extrusion in Pipe ...IJERA Editor
The objective of this paper is to study the defects in the plastic pipe, to optimize the plastic pipe manufacturing process. It is very essential to learn the process parameter and the defect in the plastic pipe manufacturing process to optimize it. For the optimization Taguchi techniques is used in this paper. For the research work Shivraj HY-Tech Drip Irrigation pipe manufacturing, Company was selected. This paper is specifically design for the optimization in the current process. The experiment was analyzed using commercial Minitab16 software, interpretation has made, and optimized factor settings were chosen. After prediction of result the quality loss is calculated and it is compare with before implementation of DOE. The research works has improves the Production, quality and optimizes the process.
Similar to A DEVELOPMENT OF QUALITY IN CASTING BY MINIMIZING DEFECTS (20)
How to Create Map Views in the Odoo 17 ERPCeline George
The map views are useful for providing a geographical representation of data. They allow users to visualize and analyze the data in a more intuitive manner.
The French Revolution, which began in 1789, was a period of radical social and political upheaval in France. It marked the decline of absolute monarchies, the rise of secular and democratic republics, and the eventual rise of Napoleon Bonaparte. This revolutionary period is crucial in understanding the transition from feudalism to modernity in Europe.
For more information, visit-www.vavaclasses.com
We all have good and bad thoughts from time to time and situation to situation. We are bombarded daily with spiraling thoughts(both negative and positive) creating all-consuming feel , making us difficult to manage with associated suffering. Good thoughts are like our Mob Signal (Positive thought) amidst noise(negative thought) in the atmosphere. Negative thoughts like noise outweigh positive thoughts. These thoughts often create unwanted confusion, trouble, stress and frustration in our mind as well as chaos in our physical world. Negative thoughts are also known as “distorted thinking”.
Instructions for Submissions thorugh G- Classroom.pptxJheel Barad
This presentation provides a briefing on how to upload submissions and documents in Google Classroom. It was prepared as part of an orientation for new Sainik School in-service teacher trainees. As a training officer, my goal is to ensure that you are comfortable and proficient with this essential tool for managing assignments and fostering student engagement.
This is a presentation by Dada Robert in a Your Skill Boost masterclass organised by the Excellence Foundation for South Sudan (EFSS) on Saturday, the 25th and Sunday, the 26th of May 2024.
He discussed the concept of quality improvement, emphasizing its applicability to various aspects of life, including personal, project, and program improvements. He defined quality as doing the right thing at the right time in the right way to achieve the best possible results and discussed the concept of the "gap" between what we know and what we do, and how this gap represents the areas we need to improve. He explained the scientific approach to quality improvement, which involves systematic performance analysis, testing and learning, and implementing change ideas. He also highlighted the importance of client focus and a team approach to quality improvement.
Ethnobotany and Ethnopharmacology:
Ethnobotany in herbal drug evaluation,
Impact of Ethnobotany in traditional medicine,
New development in herbals,
Bio-prospecting tools for drug discovery,
Role of Ethnopharmacology in drug evaluation,
Reverse Pharmacology.
Unit 8 - Information and Communication Technology (Paper I).pdfThiyagu K
This slides describes the basic concepts of ICT, basics of Email, Emerging Technology and Digital Initiatives in Education. This presentations aligns with the UGC Paper I syllabus.
Synthetic Fiber Construction in lab .pptxPavel ( NSTU)
Synthetic fiber production is a fascinating and complex field that blends chemistry, engineering, and environmental science. By understanding these aspects, students can gain a comprehensive view of synthetic fiber production, its impact on society and the environment, and the potential for future innovations. Synthetic fibers play a crucial role in modern society, impacting various aspects of daily life, industry, and the environment. ynthetic fibers are integral to modern life, offering a range of benefits from cost-effectiveness and versatility to innovative applications and performance characteristics. While they pose environmental challenges, ongoing research and development aim to create more sustainable and eco-friendly alternatives. Understanding the importance of synthetic fibers helps in appreciating their role in the economy, industry, and daily life, while also emphasizing the need for sustainable practices and innovation.
How to Split Bills in the Odoo 17 POS ModuleCeline George
Bills have a main role in point of sale procedure. It will help to track sales, handling payments and giving receipts to customers. Bill splitting also has an important role in POS. For example, If some friends come together for dinner and if they want to divide the bill then it is possible by POS bill splitting. This slide will show how to split bills in odoo 17 POS.
A DEVELOPMENT OF QUALITY IN CASTING BY MINIMIZING DEFECTS
1. International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)
Vol. 1, Issue 1, pp: (31-36), Month: April 2014 - September 2014, Available at: www.paperpublications.org
Page | 31
Paper Publications
A DEVELOPMENT OF QUALITY IN CASTING BY MINIMIZING DEFECTS
1PRASAN KINAGI, 2Dr. R.G MENCH
1,2BVB College of Engineering, Department Of Industrial and Production Engineering, Hubli
Abstract: In this paper design of experiment and FMEA techniques are combined to analyze casting defects. Attempt has been made to get optimal parameter setting for defects like cold shut and blow hole. Producing defect free casting is impossible. Defect analysis is carried using FMEA tool and Pareto analysis to know potential causes of failure and their effects along with correct actions to improve quality strength and productivity. The main objective of this paper is to optimize sand casting process parameter using DOE method through Taguchi method. Taguchi based L9 orthogonal array was used for experimental purpose and analysis was carried out using Minitab software for analysis of mean (ANOM) plot. In this paper the data collected is taken from one foundry.
Keywords: Casting, FMEA, DOE, Taguchi methodology, Pareto analysis.
1. INTRODUCTION
Casting is simply melting the metal and pouring molten metal into mold cavity, allowing the metal to solidify and then breaking up mold to remove casting. Casting as an old technique is the quickest link between engineering drawings 2nd manufacturing. It provides us with the possibility of forming wide range of shapes with wide range of materials. Casting process involves number of process parameters so it is difficult to produce defect free casting even in a controlled process, defects in casting are observed which challenges explanation about the cause of casting defects [1]. Casting defects analysis is the process of finding the potential failure cause of Occurrence of defects in the rejection of casting and taking necessary steps to reduce the defects and to improve the casting yield. [1-2]
In this paper, for casting defects analysis techniques like Pareto-chart, FMEA and DOE (Taguchi Method) are conversed in following section.
2. LITERATURE REVIEW
Now days in order to sustain in any variety of manufacturing industry we need to be competitive enough as rivals. The main thing we should concentrate on how we are going to minimize defects that occur in industry so necessary preventive actions should be taken.
Wilson et al. (1993) have defined the Root Cause Analysis as an analytical tool that can be used to perform a corrective and comprehensive, system based review of critical defects. Uday A. Dabade and Rahul C. Bhedasgaonkar [2] have put their emphasis on casting defect analysis using Design of Experiments and Computer Aided Casting Simulation Techniques. They work to analyze the sand related and method related defects in green sand casting. They applied Taguchi based orthogonal array for Experimental purpose and analysis was carried out using Minitab Software for analysis of variance and analysis of mean plot.
From literature review we came to know that application of Pareto analysis, failure mode effect analysis and design of experiment can significantly minimize the defects of manual casting operation.
3. METHODOLOGY
The study conducted in engine casing component manufacturing foundry where cold shut, blow hole, shrinkage, rib cut and sand inclusion are most important defects observed, and DOE is used for analysis of above mentioned casting defects. FMEA determines the potential failure cause of occurrence of defects in casting rejection.
2. International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)
Vol. 1, Issue 1, pp: (31-36), Month: April 2014 - September 2014, Available at: www.paperpublications.org
Page | 32
Paper Publications
FMEA is set of guidelines for identifying and prioritizing the potential failure or defects. Prioritizing the defects by finding the RPN (risk priority number).
Figure 1: Research Methodology
4. PROBLEM STATEMENT
To achieve or develop quality in casting by minimizing defects
Every 10 casting 4-6 castings are rejected.
Affecting defects are cold shut, blowhole and sand inclusion.
4.1 Objective
Identification of defects in engine casing (EICHER 298) and analysis
Identification of potential failure and causes through FMEA
Quality improvement, including reduction of variability and improved process and product performance
5. DATA COLLECTION
Simplified data from the total rejection sheet is represented in the following table. Data shows the total production per month and the data is of three months. Rejection of total Eicher-298 is given in the following Table-1.
3. International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)
Vol. 1, Issue 1, pp: (31-36), Month: April 2014 - September 2014, Available at: www.paperpublications.org
Page | 33
Paper Publications
Table-1 Rejection data sheet
Month Production Total
rejection
Cold
metal
Blow
hole
Sand
inclusion
Others
February 4210 508 202 138 96 72
March 3975 318 119 92 63 44
April 3508 186 97 30 42 17
Total 11693 1012 418 260 201 133
defects 3.60 2.20 1.70 1.13
Percent 41.7 25.5 19.7 13.1
Cum % 41.7 67.2 86.9 100.0
OTHERS
SAND
BH
CM
9
8
7
6
5
4
3
2
1
0
100
80
60
40
20
0
Percent
Cumulative Percent
1.13
1.70
2.20
3.60
Pareto Analysis
Figure 2: Pareto graph
With the help of Pareto chart, factors that influenced the rejection most are identified. The above graph shows the
percentage rejection of defects and also cumulative percentage of defects. From the above Pareto graph 3.6% cold metal
defects, 2.2% blowhole defects occur and it came it out as major defects and sand inclusion also effects.
5.1 FMEA Implementation
Table-2 FMEA for EICHER 298 casting
Defects
Potential failure
mode
Potential cause for failure
S
O
D
RPN
Blowhole
Internal voids with
depression
Moisture left in mold and core 7 6 6 252
Cold shut
Small shot like
sphere
Due to rapid solidification
before filling up of mold
8 8 5 320
shrinkage Reduction in volume Due to lack of riser system 4 4 4 64
Sand
inclusion
Inclusion of sand on
the edges of casted
surface
Improper ramming of sand 7 5 5 175
The Risk Priority Number (RPN) is determined by three risk parameters which include Severity Rating (S), Occurrence
Rating (O), and Detection Rating (D). FMEA can be divided into two phases. The first phase (Measure) is to identify the
potential failure modes and to decide the value of Severity, Occurrence and Detection, as given in Table in the second
phase (Improve), the manager should make recommendations for correct actions.
With the help of the FMEA domains of possible improvement are clearly identified and recommended for further action.
4. International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)
Vol. 1, Issue 1, pp: (31-36), Month: April 2014 - September 2014, Available at: www.paperpublications.org
Page | 34
Paper Publications
6. EXPERIMENT DETAILS
Experiments were carried out in foundry industry producing CI components. The analysis of casting defects involves selecting parameters and their levels. Performing experiments as per DOE (Taguchi method) and collect data. As per rejection analysis it was found that the component EICHER-298 rejection was maximum due to sand inclusion, blowhole and cold shut. So this component is selected for analysis by DOE method.
Proper selection of the casting parameters can results in minimum casting defects. Optimization of these casting parameters based on 3 levels and 4 factors is adopted in this paper to minimize the casting defects. L9 orthogonal array was used the design factor and their levels are shown in Table-3
Table-3 Factors and their level
Sl. no
code
Factors(units)
Levels
1
2
3
1
A
Pouring temperature
1380
1410
1440
2
B
Inoculant
0.1
0.2
0.3
3
C
Moisture content
3
3.3
3.6
4
D
Sand binder ratio
60:0.9
60:1
60:1.2
Experimental layout for L9 Taguchi orthogonal array-Total 9 experiments were carried out and response were recorded out of 10 products in %. The S/N ratio for minimum defects coming under smaller-is–better type characteristic.
7. RESULT AND DISCUSSION
Analysis of experimental results was performed using Minitab software and ANOM plots obtained are given in Table and Figure respectively.
Table-4 Results of ANOM
Factors
Levels (dB)
Optimum level
L1
L2
L3
A
- 31.21
-35.48
-31.21
1&3
B
-33.66
-32.38
-31.85
3
C
-32.69
-32
-33.22
2
D
-32.38
-31.85
-33.66
2
Optimum mean =-29.02
ANOM plot in Figure 3 indicates that %rejection is minimum at first level and third level of pouring temperature (A1&A3), third level of inoculant (B3), moisture content (C2) and sand binder ratio (C2)
Figure 3-Response graph
144014101380-31-32-33-34-350.30.20.13.63.33.0-31-32-33-34-3560:1.260:160:0.9A Mean of SN ratios BCDMain Effects Plot for SN ratiosData MeansSignal-to-noise: Smaller is better
5. International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)
Vol. 1, Issue 1, pp: (31-36), Month: April 2014 - September 2014, Available at: www.paperpublications.org
Page | 35
Paper Publications
7.1 Analysis of Experiment Result
Table-5 Summary of ANOVA
Factors
Degrees of Freedom
Sum of Squares
Mean
Squares
Contribution
%
A
2
36.46
18.23
74.27
B
2
5.19
2.59
10.57
C
2
2.24
1.12
4.56
D
2
5.19
2.59
10.57
Error
0
0
-
-
Total
8
49.09
6.45
99.97
From the results of ANOVA as shown in Table-5 it is observed that pouring temperature and inoculant have major contributions in controlling the defects. On the other hand, Sand-Binder ratio has moderate effect and the moisture content has least effect on defects.
Since the ANOVA has resulted in zero degree of freedom for error term, it is necessary to pool the factor having less influence for correct interpretation of results. After selecting the optimal level of process parameters, the final step is to predict and verify the adequacy of the model.
Experiments were conducted with optimal levels of factors obtained by Taguchi optimization. The measured values of defects under the optimal process conditions were used to determine the observed values of signal to noise ratio (ηobs).
Confirmation experiments were performed at the optimized setting of process parameters, results of which are shown in below Table-6.
In order to judge the closeness of observed value of signal to noise ratio with that of the predicted value, the variance of prediction error ( 2pred) is determined and the corresponding two-standard deviation confidence limits for the prediction error of the signal to noise ratio is calculated. From the results of conformity tests, summarized in Table7 and the Calculation is done.
It can be observed that the calculated value of prediction error is close to confidence limit, which indicates that the additive model of defects is adequate.
Table-6 Results of Confirmation experiment
Sl.no
Pouring temperature
inoculant
Moisture content
Sand- Binder Ratio
Defects
In %
S/N Ratio
1.
1380
0.3
3.3
60-0.1
20
-26.02
2.
1440
0.3
3.3
60: 0.1
20
-26.02
Average signal to noise ratio= -26.02
Table-7 Confirmatory Test Result
Levels (A, B, C, D)
1-3-2-2
Signal to noise ratio observed
(ηobs), dB
-26.02
Predicted Signal to noise ratio (ηpred), dB
-29.65
Prediction error, dB
3.63
Confidence limit ( 2σ), dB
±2.39
6. International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)
Vol. 1, Issue 1, pp: (31-36), Month: April 2014 - September 2014, Available at: www.paperpublications.org
Page | 36
Paper Publications
8. CONCLUSION
The following conclusions were drawn from the present investigation.
Pareto principle is used to identify and evaluate different defects and causes for these defects responsible for rejection of components at different stages of manual metal casting operations. The correct identification of the casting defect at initial stage is very useful for taking remedial actions.
By FMEA method, we find the potential failure mode and potential cause for failure of defect.
Defects in casting are minimized with optimal level settings of process parameters.
All factors considered contribute to the quality of performance.
The optimized levels of selected process parameters obtained by Taguchi method pouringtemperature(1380&1440),inoculant(0.3),moisture-content(3.3),sand-binder ratio(60:1)
The percentage contribution of error is within 10%, which indicates that, no important factors are left out from analysis.
REFERENCES
[1] H.C. Pandit, Amit Sata, V. V. Mane, Uday A. Dabade,2012, “A Novel Web-based system for Casting Defect Analysis”, paper published in technical transactions of 60th Indian Foundry Congress, 2-4th March2012, Bangalore,pp 535-544.
[2] Rahul Bhedasgaonkar, Uday A. Dabade, May 2012, “Analysis of casting Defects by Design of Experiments Method”, Proceedings of 27th National Convention of Production Engineers and National Seminar on Advancements in Manufacturing VISION 2020,organised by BIT, Mesra, Ranchi, India.
[3] Phadke.M.S. “Quality Engineering Using Robust Design”, Prentice Hall, International, New Jersey, 1989.
[4] Ross.P.J. “Taguchi Techniques for Quality Engineering”, McGraw Hill Inc., U.S.A, 1998.
[5] Piyush Kumar Pareek, “FMEA Implementation in a Foundry in Bangalore to Improve Quality and Reliability” International Journal of Mechanical Engineering and Robotic Research, ISSN 2278 – 0149 www.ijmerr.com Vol. 1, No. 2, July 2012- 2012 IJMERR.
[6] Prof B.R. Jadhav, Santosh 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.
[7] Mr. Deepak Kumar, Optimization of sand casting parameter using Factorial Design; Volume: 3, ISSUE 1, JANUARY 2014, ISSN No 2277-8179.
[8] Achamyeleh A. Kassie, et al Minimization of Casting Defects, IOSR Journal of Engineering (IOSRJEN) e-ISSN: 2250-3021, P-ISSN: 2278-8719 Vol. 3, Issue 5 (May. 2013), ||V1 || PP 31-38.