Modeling and Optimization of Sand Casting Process
Keywords:
Response Surface Methodology, Genetic Algorithm, Sand casting and Nonlinear modelAbstract
The manufacture of quality engine components has always been a major focus in the technological world. One of the easiest and affordable means of realizing high quality automobile components and casting integrity is sandcasting. In order to produce quality casting it will be important to carry out the experiment in a developed layout using Design of Experiment technique. A nonlinear mathematical model used for the prediction of hardness was developed by the Response Surface Methodology. ANOVA result showed that the developed model is adequate with R2 (adjusted) of 50.05% and R2 of 71.09%. The difference in the coefficient of determination values indicate that there exist over fitting in the developed model. The developed model was used as objective function in the evolutionary Genetic algorithm tool box to determine the optimal level of the process parameters. The optimal parametric setting for sand casting as investigated by the study is 6800C, 31.524Hz, 59.998 seconds and 309.696mm2 for pouring temperature, vibration frequency, vibration time and runner size respectively. A confirmatory test carried out showed that the actual experimented values are similar to the predicted values.
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