Optimization of tensile properties of evaporative pattern casting process through Taguchi's method

Kumar, Sudhir; Kumar, Pradeep; Shan, H. S.

doi:10.1016/j.jmatprotec.2007.10.075

Cited by 63 publications

(49 citation statements)

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“…In order to obtain castings with good surface finish free from defects researchers both in industries and academia are giving attention to both experimental, modeling and theoretical studies of the variables known to influence the process [2,6,[12][13][14][15][16][17]. It has been recognized that the pyrolysis products are the main source of defects in EPC [11,18].…”

Section: Advanced Casting Technologies 90mentioning

confidence: 99%

“…The term 'evaporative' stands as a family name for all the trade names that have so far been coined out for evaporative pattern casting processes. This is because the pattern evaporates when there is contact between it and liquid metal; all the features are replicated [6]. …”

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“…However, predictions have been made that soon very many foundries would use the process; looking at it from the perspective of automotive industries. It is believed that if the process parameters that affect the EPC process are properly monitored and controlled and there is proper gating system design and melting and pouring practices, defect free castings should be obtained [5].In order to obtain castings with good surface finish free from defects researchers both in industries and academia are giving attention to both experimental, modeling and theoretical studies of the variables known to influence the process [2,6,[12][13][14][15][16][17]. It has been recognized that the pyrolysis products are the main source of defects in EPC [11,18].…”

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“…Magnesium and it alloys are now being cast using the method. The first public recognition of the application of the process was in 1980 when General Motors produced some automobile components with it [6,7,31]. Aluminum railway valve body, aluminum cylinder head, pipe fittings and shaft hubs are now being produced by foundries in Canada, Italy, USA and Netherlands [32].…”

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“…The molten metal displaces the foam because of its high temperature; resulting in pyrolysis products like monomers and emissions toxic to human [13]. All the products formed in the mold have been established as potential causes of defects in castings obtained by EPC process Evaporative Pattern Casting (EPC) Process http://dx.doi.org/10.5772/intechopen.73526 99 [6,43,45,49,50]. Attempts have been made to study comprehensively the behaviour of the liquid metal poured into EPC molds.…”

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Evaporative Pattern Casting (EPC) Process

Omidiji¹

2018

Advanced Casting Technologies

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The chapter provides details of operations and activities in evaporative pattern casting (EPC) Process. The process was developed in the year 1956 to tackle some of the inadequacies of the traditional sand casting processes but has in itself some challenges that should be taken care of if sound castings would be obtained. The challenges come mainly from the evaporative pattern employed as pattern material in the process. The material makes the process to be sensitive to process variables such that proper and adequate control should be ensured to have castings of sound integrity. Some of the known process variables are pouring temperature, refractory coating, vibration and pattern and molding materials. In the whole the EPC is known to have edge over the traditional sand casting methods.Keywords: pattern, molding, casting, variables and coating History of evaporative pattern casting (EPC) processEvaporative pattern casting (EPC) Process is a sand molding process that makes use of evaporative patterns produced industrially by steam molding or machined out from a block of expandable polystyrene foam (EPS) [1,2]. The pattern is buried in the sand mold and the melted casting material is poured into the mold without removing pattern, unlike the traditional sand casting method that makes use of wooden, plastic and metallic pattern which is removed from the mold before molten metal is advanced.It was in 1956 that Shroyer made a documentation of his work on EPC where green sand was used as the molding material [3]. The author machined a shape from expanded polystyrene (EPS) and supported it inside a flask with bounded sand. Another researcher called Flemmings © 2018 The Author(s). Licensee IntechOpen. This chapter is distributed under the terms of the Creative Commons Attribution License (http://creativecommons.org/licenses/by/3.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.came up in 1964 to use unbounded silica grains for the process [1]. Foundry men later came to differentiate between the two; calling the first the full mold and the second the lost foam processes. The subtle difference only lied in the use of bounded (green) sand and loose sand.The process became known to foundry men in 1958 and many trade names have been formed to describe it [3]. They include styrecast, replicast, full mold, lost foam and evaporative process. A distinguishing feature of this type of sand process is that an evaporative pattern made of polystyrene foam is used [4]. It is coated with a coating developed from a refractory material usually silica or zircon sand before being buried in the mold. It is not removed from the mold once it is buried.After 1964, some works have been done by researchers to understand the variables that affect the process. Some works in the automotive industry have also been done. General motors have produced a number of automotive components with the method. This started in the year 1980 and they are still in the use of the p...

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Section: Advanced Casting Technologies 90mentioning

confidence: 99%

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