Design & Analysis Of Casting Process Of Mill Roller: A Case Study Of Akaki Basic Metals Industry

Abstract

Akaki Basic Metals Industry Foundry Suffers From Poor Quality And Productivity Due To Involvement Of Number Of Process Parameters. The Quality Characteristics Of The Mill Roller In Sand Casting Has Been Affected By Casting Defects Caused By In Proper Process Parameter Usage And Intern Affects Its Proper Function That Lead To Large Number Of Shop Floor Trials, High Rate Of Rejection And Low Casting Yield. The Objective Of This Research Is To Design And Analyze Sand Casting Process Of Mill Roller. In This Research Work Methods Like Critical Observation, Interview, Discussion, Numerical Experimentation And Simulation Were Done At Abmi Foundry. Solid Modeling Of Mill Roller Component With All Incorporating Gating System Was Carried Out By Solidwork Software And Simulation Process Was Carried Out By Using Procast Software For The Mould Filling And Solidification Analysis To Reduce The Level And Intensities Of Shrinkage Porosities In Cast Mill Roller. Taguchi Method Of Numerical Experimentations Was Carried Out For Parameter Optimization And Analysis Of Variance (Anova) Using Minitab Software. The Confirmatory Test With The Optimal Level Of Casting Process Parameters Were Carried Out. The Casting Process Parameters Of The Mill Roller Were Identified By Using Cause And Effect Diagram And The Parameters Were Permeability, Pouring Temperature And, Moisture Content. Based On The Numerical Results And Their Interpretation, The Optimal Values Of The Parameters Were Determined To Eliminate The Defects. The Optimum Settings Of The Selected Process Parameters Of The Mill Roller Was Found As Permeability 145 (No), Pouring Temperature 1300??? And Moisture Content 2.5%. The Percent Contribution Of Each Factor Were Also Determined And Found As Permeability 61.35%, Pouring Temperature 21.64% And Moisture Content 2.95%. The Improvement In Minimizing The Casting Defects Of Mill Roller Was 48.29 Percent. Using Simulation Software, Shrinkage Porosity Was Observed In Both Gating System And Roller Part.