This study has been performed to seek the optimum casting plan for the green sand mould of the thin sectional ring castings, about 100mm int. dia., 4∼7.5mm thickness (tapered) and 50mm height. Sixteen flasks of test castings (two castings in each flask) were made varying the seven factors which were expected to have influences on the soundness of castings, and the defects, hardnesses and their flucuations were measured. Data were analyzed by using the L
16 (2)
16 type of orthogonal arrangement of experimental designs.
Factors and levels selected were as follows:
Factors Levels
Arrangement of casting Cope, Drag
Directin of Gates Rectangular, Tangential to the Castings
Sectional Area of Gates 100mm
2, 40mm
2 Pouring Method Use, No Use of the Stopper
Vent of Mould Applied, Not Applied
Moisture Content of Sand 4%, 6%
Pouring Temperature 1,400°C, 1,350°C
Moulds were made by a moulding machine with jolt, squeese and stripper, jolting being applied ten times each. Moulding sands were composed of 90 parts of old sand, including 5 per cent bentonite, and 10 parts of new silica sand. 1 per cent bentonite and 0.3 per cent starch were added to them.
Iron used had a tensile strength of about 25 kg/mm
2 and was melted in a water-cooled cupola. Tapping temperature was about 1,500°C.
Pin holes and sand scab inclusions appeared in the test castings. Their number and size were measured on the internal surface of the ring machined by 0.8mm. Rock well C hardnesses were obtained at 16 points on the both ends and the middle section of the ring. Means and standard deviations of hardness on each surface were calculated, stress being put on the data about the thinner section end.
Analysis of the data by means of the experimental design showed that the pouring temperature gave the strongest influence to the soundness of castings, and the effects of the direction of gates and the arrangement of castings came second.
Poring temperature effected the pin holes and the hardnesses at the thinner section end and the middle section. Pin holes and hardnesses increased with low temperature pouring. The end sections were chilled in some cases. The direction of gates had a concern in the fluctuation of the hardnesses of thinner section end, gates directed tangential to the castings made the fluctuation smaller. Whether the castings are put in the drag or cope gave contrary results by the interaction with other factors, however, putting in the drag showed rather better results.
The stopper had more or less concern in the sand inclusions defects, that is, a rapid pouring by the use of the stopper caused many sand inclusions. But as the contribution rate of error was large in the analysis of the data for the sand inclusions, it was considered there were effects of factors which were not included in the data of this experiment, for example a strength of moulding sand.
Effects of other factors, that is, the sectional area of gate, the vent of mould and the moisture of moulding sand were little recognized.
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