Parametric optimizing green sand-casting process parameters using hybrid Taguchi grey relational analyses and principal component analyses

Abstract

The Green Sand-casting technique is a very ancient method of casting that has many different uses. The increased rate of errors and rejection in this process is a key drawback that reduces output and profits. It’s challenging to develop a good link between the many different parameters and defects since the process is so complicated. This article describes a hybrid approach to find the co-relation for sand casting process’s variables. This approach mixes the Taguchi method (TM) with Grey Relational Analysis (GRA) paired with Principal Component Analysis (PCA). Moisture content, Permeability, Loss of Ignition, Pouring Time & Pouring Temperature selected as input parameters while types of defects (Shrinkage, Blow holes, Cracks, Porosity) as responses for proposed study. The L27 OA from Taguchi is used to plan the tests. TM implemented to analyse individual responses. GRA is applied to find optimal solutions for a set of replies, whereas PCA is used to determine how much weight each response should be given. Using proposed methodology, 4% moisture content, 160% permeability, 5% loss of ignition, 60 seconds of pouring time, and 1400°C found as optimum set of parameters. The findings demonstrate that the hybrid approach, which makes use of both a cost-effective and efficient experimental design strategy, was successful in resolving the complexity trade-off experienced throughout the judgment process of multi-response optimization.