Design and analysis of sand casting process of mill roller

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 have been done. Solid modeling of mill roller component with all incorporating gating system has been carried out by solidwork software and simulation process has been carried out by using ProCAST software for the mold filling and solidification analysis to reduce the level and intensities of shrinkage porosities in cast mill roller. Taguchi method of numerical experimentations has been carried out for parameter optimization and analysis of variance (ANOVA) using Minitab software. The confirmatory test with the optimal level of casting process parameters have been carried out. The casting process parameters of the mill roller have been identified by using cause and effect diagram. The parameters such as permeability, pouring temperature, and moisture content have been taken into consideration. Based on the numerical results, their interpretation and the optimal values of the parameters have been determined to eliminate the defects. The present research work has shown in the improvement of casting yield. It has been found that the casting defects are minimized by 2.98%. The results also reveal that sand sintering problem and porosity defects occurred in the mill roller castings were due to the weak sintering strength of fine mixed molding silica sand used in the process. Using simulation software, shrinkage porosity has been observed in both gating system and roller part.