LAUSR

Abstract Casting defects account great threat to a growing foundry, since it is directly related to the economy. In this work, grey cast pump adapter casting process in a foundry is optimized to produce quality castings using design of experiments (DOE) and Computer aided Engineering (CAE) approaches. Prominent parameters like clay percentage, moisture percentage and mould hardness are considered for performing DOE with three different levels of Box–Behnken Design. Experimental trials were conducted and number of defective components was measured. Results are evaluated using Design Expert Evaluation software to obtain optimal settings. Analysis of Variance test revealed contribution level of each parameter in the casting process. DOE is an efficient tool to optimize casting process that can produce quality castings. In addition, possible defects in castings are analysed using CAE technique (PROCAST simulation software). Simulation using PROCAST is carried out to investigate internal defects by carefully designing gating and feeding parameters in pump adapter castings. Bottom filling is encouraged in the mould cavity to control metal filling process. It can be inferred that DOE and CAE PROCAST simulation has enabled to achieve uniform cooling rate and directional solidification to produce defect free grey cast pump adapter castings.