Optimization of Green Sand Casting Parameters Using Taguchi Method to Improve the Surface Quality of White Cast Iron Grinding Plates - A Case Study

This research focuses on the optimization of parameters in green sand casting process; specifically to improve the surface quality of white cast iron grinding plates using statistical design of experiments techniques. Four controllable factors; Bentonite (A), charcoal (B), water content (C), sand mixing time (D) and one noise factor; pattern (E) were considered as the influential factors which have an impact on surface quality of the cast grinding plate. Taguchi method was used as the experimental method to conduct the experiments. The analysis of the experiment shows that main factors A (p = 0.061), D (p = 0.021), B (p = 0.180) and AB (p = 0.060) two way interaction have a significant impact (at 10% significance level) on surface quality of grinding plates. Finally, the results obtained through the confirmation run verified the optimum parameter settings produced by the Taguchi method gives robust solutions to improve the surface quality of grinding plates successfully.