OPTIMIZATION OF CASTING PROCESS BASED ON BOX BEHNKEN DESIGN AND RESPONSE SURFACE METHODOLOGY

Sound and accurate castings reveal the quality of a foundry unit. In this case study, an attempt has been made to optimize the production of grey cast pump adapter castings using Box - Behnken design of experiments (DOE) approach in a foundry producing grey cast iron components. Process parameters like Clay percentage, Moisture percentage and Mold hardness were found to be dominant factors to control during the production process. Three different levels of each factor were considered for experimentation using BBD. Experimental trials were conducted using the design matrix and response in each experiment was measured and the results were tabulated. Design Expert software was used to analyse and optimize process parameters for confirmatory experiments. Analysis of Variance (ANOVA) test was conducted to identify significant parameters. The parametrical settings of the confirmatory experiments produced defect free pump adapter castings. The effects of variation of the process parameters and their influence on the quality of the castings were discussed. The research concluded that careful adjustment of process parameters is necessary since bonding strength is directly related to these parameters; in turn have an effect on the quality of castings produced.