Optimization and empirical studies of riser design in sand casting process using different mould properties

Sand casting is a crucial manufacturing step in creating a quality product that will meet the demands of the market. Four common metals aluminum, brass, gunmetal, and cast iron are evaluated to determine which makes the best riser. In this study, we use Taguchi L9 orthogonal array design of experiment (DOE) analysis to the melting and vent hole characteristics of sand and develop a mathematical model using Taguchi methods. It is necessary to concentrate the size and geometry of the riser. The riser design is optimized by process parameters of major diameter, minor height, and diameter of the riser. By balancing many factors, including riser design, melting, sand, and vent holes, we found the optimal configuration. The end objective is to improve the material’s mechanical properties. As a result of its superior dimensional geometry, simplicity of pattern development, higher production rate, and decreased solidification time compared to another casting, investment casting has become increasingly popular. It is common to practice casting both ferrous and non-ferrous materials in the sand since doing so yields a high-quality, low-cost item. Most of the small-scale industries are making the cast material by sand casting process that observed the yield of casting ranges from 50 to 55% only. 50%on the raw material is spent for the riser, runner, and gating system. Out of 50%, the riser alone has 25% of the raw material. It is clear that, the riser having more volume of raw material.