M. Nandagopal

Bio: M. Nandagopal is an academic researcher from Bannari Amman Institute of Technology, Sathy. The author has contributed to research in topics: Sand casting & Casting. The author has an hindex of 1, co-authored 5 publications receiving 2 citations.

Multi-objective optimization of western bentonite (Al2H2Na2O13Si4)-blended green sand casting process parameters to improve mould quality

Abstract: The quality of the mould in green sand-casting process plays a vital role to achieve good quality castings. In this research work, the main mould properties such as permeability and hardness are fo...

Review on ferrous and non-ferrous casting defects and their analysis

Abstract: The castings can be produced by using sand moulds and permanent dies. The rejection rate is more in sand casting process due to more number of process parameters. The papers reviewed about the defects occurred in the most widely used ferrous and non-ferrous materials such as cast iron, steel and aluminum are referred for this work. The defects are analyzed using various types of experiments, optimization techniques and software. This paper is useful to researchers and industrial persons to know about the tools available to analyze the defects and remedial action can be taken for the defects.

Optimization of Process Parameters to Reduce the Green Sand Casting Defects

Abstract: In this work, the mold-related sand casting defects are minimized by using the Taquchi optimization technique. The parameters considered are water content percentage, green compression strength (GCS), hardness of the mold, and molding sand particle size. The L9 orthogonal array is used to conduct the experiments. The outcome of this work leads to the sand casting foundry men to select the suitable level of process parameters to produce good quality castings. The improvement expected is around 8–10% reduction in mold-related casting defects.

Pengendalian kualitas continuous tandem cold mill (CTCM) menggunakan metode Taguchi pada divisi cold rolling mill di PT. XYZ

Abstract: Kualitas menjadi hal yang paling utama dan mendasar bagi pelanggan, yaitu ketika produk yang didapatkannya berada dalam keadaan baik dan tidak terdapat kecacatan atau defect. Dengan kondisi seperti ini, perusahaan dituntut memproduksi produk yang berkualitas baik dengan tingkat kecacatan atau defect seminimum mungkin agar dapat meningkatkan profit perusahaan. PT. XYZ merupakan salah satu industri baja terbesar di Indonesia yang senantiasa menjaga produknya dengan kualitas yang tinggi tetapi masih terdapat produk yang memiliki kecacatan atau defect. Pada Tahun 2019, kecacatan yang terjadi pada continuous tandem cold mill (CTCM) untuk produk cold rolled coil (CRC) mencapai 29.918 ton dari total produksi 282.863 ton atau sekitar 10% dari total produksi. Oleh karena itu peneliti melakukan penelitian terkait kecacatan (defect) yang terjadi untuk produk cold rolled coil (CRC) pada continuous tandem cold mill (CTCM). Penelitian terhadap kualitas produk cold rolled coil (CRC) dilakukan dengan menggunakan diagram Pareto, peta kendali p, diagram fishbone, metode Taguchi dan ANOVA. Berdasarkan hasil penelitian yang dilakukan, didapatkan bahwa cacat yang dominan terjadi adalah cacat F70A (serrated edge) dan untuk meminimalisir cacat tersebut didapatkan setting level yang optimal yaitu temperatur coil sebesar 8900C dan break cut area dengan ≥40% area pemotongan atau pemakanan coil. The most basic thing in quality in the eyes of customers is when the product they get is in good condition and there are no defects. With these conditions, companies are required to produce products with minimum defects or no defects in order to increase company profits. PT. XYZ. is the largest steel industry in Indonesia which always maintains its products with high quality but there are still products that have defects. In 2019, defects occurred in the continuous tandem cold mill (CTCM) mill for cold rolled coil (CRC) reached 29.918 tons from a total production of 282.863 tons or about 10% of total production. Therefore, researchers conducted research related to defects that occur for cold rolled coil (CRC) products in continuous tandem cold mill (CTCM). Research on the quality of cold rolled coil (CRC) products was carried out using Pareto diagrams, p-control charts, fishbone diagrams, and the Taguchi method. Based on the results of the study, it was found that the dominant defect occurred was F70A (serrated edge) defect, then to minimize the defect, the optimal setting level was obtained, that is coil temperature of 8900C and the break cut area with ≥40% of the cutting area or coil feeding. Tersedia pada: http://dx.doi.org/10.36055/tjst.v16i2.9242.

Parametric analysis of mould sand properties for flange coupling casting

Abstract: In this research, the analysis of ramming factor, wall thickness, and quantity of additives powder have been considered on the permeability of mould which is used to make flange coupling cast. The data has been collected from the mould sand making industry using L27 orthogonal array. It was revealed from the analysis that the maximum permeability has been obtained from the lowest ramming factor, thin wall thickness, and minimum mixing of additives. The mould permeability number increased significantly to the proper allowability of gas from the mould cavity. The surface finish of the outer wall of the casting had been improved with minimum backpressure formation by increasing permeability number. The confirmation tests were conducted to validate the predicted process parameter on responses.

A cfd investigation into molten metal flow and its solidification under gravity sand moulding in plumbing components

Abstract: : Metal casting using the solidification of molten metal flows involves complex heat transference during production. This can cause defects in the workpiece, affecting the efficiency of production. This research will use the Computational Fluid Dynamics (CFD) technique to investigate the filling, solidification, and cooling stages of the production of a component for plumbing. The CFD program FLOW 3D CAST v5.03 tracked the leading edge of the molten metal liquid (based on the Volume of Fluid (VOF) method). A two-equation k–ɛ turbulence was adopted to provide a Reynold term, and it should be noted that the geometry of the molten liquid and the internal chamber is the same as in the actual production line. The simulation shows how different pouring temperatures affect the runner, and that the pouring temperature influenced the behavior of the molten metal flow, resulting in defects on the workpiece. Moreover, the runner and its number affected the liquid metal flow and affected the defect's location during the solidification period. Future work will verify the results between the simulation and experiments, and further investigate possible defect locations on the surface of the workpiece, which could be a critical criterion in further discussions.