Optimization of Process Parameters Affecting the Surface Roughness in Sand Casting of Al6063 Alloy Using Design of Experiments
Abstract
Casting is one of the most effective production techniques for developing a product that meets the demands and expectations of the customer. Sand casting is an effective technique among numerous casting processes because it is efficient and adaptable to deliver castings of any material. The Al6063 alloy was melted in a crucible furnace, and a product is developed using the sand-casting technique in the present work. According to the Design of Experiments (DoE) recommendations, the input process parameters such as molten temperature, pouring time, and cavity holding time were selected and examined at three distinct levels. Experiments were carried out using an L9 orthogonal array, and analysis of variance (ANOVA) was used to determine the most critical input process parameter. Surface roughness and S/N ratio averages are calculated and displayed for various control parameters. The best parameters for sand casting Al6063 for a better surface finish are 700oC molten temperature, 20 seconds pouring time, and 40 seconds cavity hold time. The results revealed that molten temperature has the most significant impact on surface roughness, followed by pouring time, with cavity holding time having little effect. Finally, the regression analysis-derived mathematical model by MINITAB-17 may be used to predict surface roughness.
