Defect Minimization in Casting through Process Improvement-A Literature Review

S, Patil Sachin; R, Naik Girish

doi:10.9790/1684-1402010913

Cited by 3 publications

(2 citation statements)

References 4 publications

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“…This research is going to help the small foundries in implementing Six Sigma initiatives within their businesses, enhancing their performance in terms of client happiness and financial rewards, and improving their standing in the international foundry industry. A review of the literature on defect minimization in casting by process improvement was performed by Patil Sachi and Naik Girish [3]. The whole manuscript provides a thorough analysis of past efforts on process improvement strategies for casting defect minimization.…”

Section: Literature Surveymentioning

confidence: 99%

Review on Automated Casting Fault Separation Machine

Muthukumar,

Bhuvanesh,

Mahendran

et al. 2024

AMM

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Currently, the manufacturing industries play an important part in the global economy. I t is critical for the industries to maintain the high standards of goods and products. Various machines / systems have been developed for determining dimensional stability or the lack of filling in a casting product, thereby rejecting the defective products. The existence of the casting product is detected using an infrared or ultrasonic sensor. When a product arrives along the conveyer, the sensor can detect its measurements. If the product has the necessary proportions and dimensions, it is moved to the accepted bin; otherwise, it is denied by a pneumatic actuator and placed in the rejecter bin. Eventually, a profound learning model that categorizes into two different categories has been studied to automate the manual inspection procedure in the casting failure system. This automated casting fault separation machine is accurate, reliable and low cost which makes it suitable for small scale industries with easy segregation of high quality products. The objective of this paper is to review the various automatic systems developed for separating casting fault.

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Section: Literature Surveymentioning

confidence: 99%

Review on Automated Casting Fault Separation Machine

Muthukumar,

Bhuvanesh,

Mahendran

et al. 2024

AMM

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“…This not only resulted in substantial revenue losses, given a unit cost of 5000/-per housing but also highlighted the potential for process improvement. The study proposes that a combination of simulation techniques and design of experiments can be employed to effectively minimize defects in the product under investigation [1].…”

Section: Literature Reviewmentioning

confidence: 99%

Reinventing quality in foundry castings through gearbox housing optimization: A case study approach

Patil Sachin S,

Naik Girish R,

Naik Poornima G

2023

Global J. Eng. Technol. Adv.

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The Indian Foundry cluster is a key player in the production of metal castings used across various industries, including automobiles, railways, machinery, sanitary appliances, pipes, gears, earth-moving equipment, cement, electric circuits, pumps, valves, and wind turbines. Grey iron is the predominant material, constituting around 68% of all cast parts. In this context, Kolhapur plays a pivotal role in the production of diverse castings in India, primarily focusing on grey iron and SG iron castings, both of which are ferrous materials. The Kolhapur Cluster of Foundries is expected to produce approximately 650,000 tonnes annually, contributing about 7% of India's total cast iron production. However, this cluster encountered challenges related to higher rejection rates for castings due to a variety of defects. One established foundry in Kolhapur faced stricter rejection standards for specific castings. To address these issues, a comprehensive case study was conducted to reduce rejection rates in this foundry. The primary focus of the study was on a specific casting, the Gearbox Housing, which had an initial average rejection rate of 13%. In some instances, this rejection rate spiked to as high as 18% in a single month, resulting in significant revenue losses for the company. The defects observed in Gearbox Housing castings were categorized into two main types: Methoding, Filling, and Solidification-related defects, which included issues like shrinkage porosity and hot tears. Sand and mold-related defects, such as sand inclusion, sand drop, and mold quality issues. The initial step in addressing these defects involved utilizing casting simulation techniques to analyze and tackle shrinkage and porosity issues. A new gating system was designed to enhance the casting process. In the subsequent stage of defect reduction, the Design of Experiment (DoE) tool was employed. This data-driven approach helped refine and optimize the manufacturing process to minimize defects and enhance the overall quality of Gearbox Housing castings. By implementing these strategies, the foundry in Kolhapur successfully reduced rejection rates, thereby safeguarding company revenue and ensuring the production of high-quality castings for various industrial applications.

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Thermal hot spot prediction in high pressure die casting by determination of Chvorinovs rule shape constant

Marathe¹,

Quadros

2021

Materials Today: Proceedings

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Defect Minimization in Casting through Process Improvement-A Literature Review

Cited by 3 publications

References 4 publications

Review on Automated Casting Fault Separation Machine

Review on Automated Casting Fault Separation Machine

Reinventing quality in foundry castings through gearbox housing optimization: A case study approach

Thermal hot spot prediction in high pressure die casting by determination of Chvorinovs rule shape constant

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