Quality improvement of a casting process using design of experiments Mejoramiento de la calidad de un proceso de fundicion utilizando diseno de experimentos
In order to minimize the castings which do not meet the customer acceptance specifications, it is not only necessary to identify the process parameters related to the specific defects, but also it is necessary to identify the levels of these parameters to produce acceptable castings. This research study, was aimed to optimize the production of grey cast pump impellent castings using Response Surface Methodology (RSM) approach in a foundry producing grey cast iron components. Process factors like clay percentage, moisture percentage and mold hardness were found to be dominant factors for production process control. Three different levels of each factor were considered for experimentation. Statgraphics Centurion Statistical Software was used to analyze and optimize process parameters for further confirmatory experiments. Significant parameters were identified by means of an Analysis of Variance (ANOVA) test. Parameter optimal settings obtained, and validated from confirmatory experiments, produced a high per cent of defect free pump impeller castings. The research concluded that careful adjustment of process dominance parameters is necessary, since they have significant effects on quality improvement of castings produced.