Inclusive Module to foster SMEs for Defect Identification in Sand Casting

International Journal of Mechanical Engineering
© 2024 by SSRG - IJME Journal
Volume 11 Issue 6
Year of Publication : 2024
Authors : Nirav Mehta, Sachindra Doshi, Sanjay Zala, Nishadevi Jadeja, Amisha Pathak, Devendra Marsonia
pdf
How to Cite?

Nirav Mehta, Sachindra Doshi, Sanjay Zala, Nishadevi Jadeja, Amisha Pathak, Devendra Marsonia, "Inclusive Module to foster SMEs for Defect Identification in Sand Casting," SSRG International Journal of Mechanical Engineering, vol. 11,  no. 6, pp. 92-104, 2024. Crossref, https://doi.org/10.14445/23488360/IJME-V11I6P111

Abstract:

Even with extreme caution while producing casting components, flaws will inevitably arise due to the broad range of variables that can go wrong during the specific phases of pattern, moulding, melting, pouring, heat treating, etc. Accurately identifying flaws and taking corrective action requires real experience and information gathered over time. Small and medium-sized casting companies, however, try to locate and hire quality specialists for fault identification. Research on creating a module to help SMEs identify defects and become less reliant on human expertise was presented. The most crucial step in the casting defect analysis procedure was creating a structural database, which was accomplished by assessing the literature and applying it practically. Developing a module to detect casting defects and provide corrective actions was part of the present research. The physical characteristics of the casting flaw were used to identify it, and the appropriate remediation was then performed. Both experts and novices can utilize the computer-assisted created module to solve the problem. The module’s confirmation was also achieved by doing a defect analysis in the casting sector to remedy the casting flaw.

Keywords:

Casting defects, Defect identification, Defect analysis module, Expert system, Sand Casting.

References:

[1] Mark Jolly, “Casting Simulation: How well do Reality and Virtual Casting Match? State of the Art Review,” International Journal of Cast Metals Research, vol. 14, no. 5, pp. 303-313, 2002.
[CrossRef] [Google Scholar] [Publisher Link]
[2] S.N. Dwivedi, and A. Sharan, “Development of Knowledge-Based Engineering Module for Diagnosis of Defects in Casting and Interpretation of Defects by Nondestructive Testing,” Journal Material Processing Technology, vol. 141, no. 2, pp. 155-162, 2003.
[CrossRef] [Google Scholar] [Publisher Link]
[3] B.K. Chakrabarty, “Expert System: A Tool for Expert Decision,” Transactions of the Indian Ceramic Society, vol. 61, no. 3, pp. 118-121, 2002.
[CrossRef] [Google Scholar] [Publisher Link]
[4] M. Cemal Cakir, and Kadir Cavdar, “Development of a Knowledge-Based Expert System for Solving Metal Cutting Problems,” Materials and Design, vol. 27, no. 10, pp. 1027-1034, 2006.
[CrossRef] [Google Scholar] [Publisher Link]
[5] A. Diószegi et al., “Defect Formation of Gray Iron Casting,” International Journal of Metalcasting, vol. 3, pp. 49-58, 2009.
[CrossRef] [Google Scholar] [Publisher Link]
[6] M.W. Fu, and M.S. Yong, “Simulation-Enabled Casting Product Defect Prediction in Die Casting Process,” International Journal of Production Research, vol. 47, no. 18, pp. 5203-5216, 2009.
[CrossRef] [Google Scholar] [Publisher Link]
[7] Sushil Kumar, P.S. Satsangi, and D.R. Prajapati, “Optimization of Green Sand Casting Process Parameters of a Foundry by Using Taguchi’s Method,” The International Journal of Advanced Manufacturing Technology, vol. 55, pp. 23-34, 2011.
[CrossRef] [Google Scholar] [Publisher Link]
[8] Wim J.C. Verhagen et al., “A Critical Review of Knowledge-Based Engineering: An Identification of Research Challenges,” Advanced Engineering Informatics, vol. 26, no. 1, pp. 5-15, 2012.
[CrossRef] [Google Scholar] [Publisher Link]
[9] Uday A. Dabade, and Rahul C. Bhedasgaonkar, “Casting Defect Analysis using Design of Experiments (DoE) and Computer Aided Casting Simulation Technique,” Procedia CIRP, vol. 7, pp. 616-621, 2013.
[CrossRef] [Google Scholar] [Publisher Link]
[10] Joseph C. Chen, and Abhilash Reddy Buddaram Brahma, “Taguchi-Based Six Sigma Defect Reduction of Green Sand Casting Process: An Industrial Case Study,” Journal of Enterprise Transformation, vol. 4, no. 2, pp. 172-188, 2014.
[CrossRef] [Google Scholar] [Publisher Link]
[11] Harshwardhan Pandit, Amrita Mangarulkar, and Uday Dabade, “Development of New Prototype Interactive System for Casting Defect Identification and Analysis,” Applied Mechanics and Materials, vol. 197, pp. 433-437, 2012.
[CrossRef] [Google Scholar] [Publisher Link]
[12] V. Naranje, and S. Kumar, “A Knowledge-Based System for Automated Design of Deep Drawing Die for Axisymmetric Parts,” Expert Systems with Applications, vol. 41, no. 4, pp. 1419-1431, 2014.
[CrossRef] [Google Scholar] [Publisher Link]
[13] Carlos Toro, Iñigo Barandiaran, and Jorge Posada, “A Perspective on Knowledge Based and Intelligent Systems Implementation in Industry 4.0,” Procedia Computer Science, vol. 60, pp. 362-370, 2015.
[CrossRef] [Google Scholar] [Publisher Link]
[14] Haocheng Tan, “A Brief History and Technical Review of the Expert System Research,” IOP Conference Series: Materials Science and Engineering, vol. 242, pp. 1-6, 2017.
[CrossRef] [Google Scholar] [Publisher Link]
[15] S. Kluska-Nawarecka et al., “Computer-Assisted Integration of Knowledge in the Context of Identification of the Causes of Defects in Castings,” Archives of Metallurgy and Materials, vol. 59, no. 2, pp. 743-746, 2014.
[CrossRef] [Google Scholar] [Publisher Link]
[16] Avinash Juriani, “Casting Defects Analysis in Foundry and Their Remedial Measures with Industrial Case Studies,” IOSR Journal of Mechanical and Civil Engineering, vol. 12, no. 6, pp. 43-54, 2015.
[Google Scholar] [Publisher Link]
[17] T. Elbel, Y. Králová, and J. Hampl, “Expert System for Analysis of Casting Defects – ESVOD,” Archives of Foundry Engineering, vol. 15, no. 1, pp. 1-4, 2015.
[CrossRef] [Google Scholar] [Publisher Link]
[18] Cindy Sithole, Kasongo Nyembwe, and Peter Olubambi, “Process Knowledge for Improving Quality in Sand Casting Foundries: A Literature Review,” Procedia Manufacturing, vol. 35, pp. 356-360, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[19] Mahantesh M. Ganganallimath et al., “Application of Taguchi-based Six Sigma Method to Reduce Defects in Green Sand Casting Process: A Case Study,” International Journal of Business and Systems Research, vol. 13, no. 2, pp. 226-246, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[20] M. Wankhede Dhananjay, B.E. Narkhede, and S.K. Mahajan, “Identification of Prominent Casting Defects and its Impact on Quality of Castings,”Smart Journal of Business Management Studies, vol. 13, no. 2, pp. 1-15, 2017.
[CrossRef] [Google Scholar] [Publisher Link]
[21] M.A. Omprakas et al., “Analysis of Shrinkage Defect in Sand Casting by Using Six Sigma Method with Taguchi Technique,” IOP Conference Series: Materials Science and Engineering, vol. 1059, no. 1, pp. 1-10, 2021.
[CrossRef] [Google Scholar] [Publisher Link]
[22] Cindy Sithole, Kasongo Nyembwe, and Peter Olubambi, “Process Knowledge for Improving Quality in Sand Casting Foundries: A Literature Review,” Procedia Manufacturing, vol. 35, pp. 356-360, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[23] Robert Sikaet al., “Application of Instance-Based Learning for Cast Iron Casting Defects Prediction,” Management and Production Engineering Review, vol. 10, no. 4, pp. 101-107, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[24] C. Chelladurai et al., “Analyzing the Casting Defectsin Small Scale Casting Industry,” Materials Today: Proceedings, vol. 37, no. 2, pp. 386-394, 2021.
[CrossRef] [Google Scholar] [Publisher Link]
[25] Mahantesh M. Ganganallimath et al., “Application of Taguchi-based Six Sigma Method to Reduce Defects in Green Sand Casting Process: A Case Study,” International Journal of Business and Systems Research, vol. 13, no. 2, pp. 226-246, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[26] Robert Sika et al., “Decision Support System in the Field of Defects Assessment in the Metal Matrix Composites Castings,” Materials, vol. 13, no. 16, pp. 1-27, 2020.
[CrossRef] [Google Scholar] [Publisher Link]
[27] C. Chelladurai et al., “Analyzing the Casting Defects in Small Scale Casting Industry,” Materials Today: Proceedings, vol. 37, no. 2, pp. 386-394, 2021.
[CrossRef] [Google Scholar] [Publisher Link]
[28] Jon Sertucha, and Jacques Lacaze, “Casting Defects in Sand-Mold Cast Irons—An Illustrated Review with Emphasis on Spheroidal Graphite Cast Irons,” Metals, vol. 12, no. 3, pp. 1-80, 2022.
[CrossRef] [Google Scholar] [Publisher Link]