The Taguchi method is a powerful problem solving technique for improving process performance, yield and productivity. Green sand casting process involves many process parameters which affect the quality of the castings produced. An analysis of significant process parameters of green sand casting process is made in this paper. The parameters considered are Green strength, moisture content, permeability and mould hardness. Using Taguchi analysis the effect of various process parameters at different levels on casting quality is analyzed and optimal settings of the various parameters have been accomplished. The outcome of this paper is the optimized process parameters of the green sand casting process which leads to improved process performance, reduced process variability and thus minimum casting defects. Also a neural network model is developed to map the complex non-linear relationship between process conditions and quality characteristic, namely casting defects.

Keywords: Green sand casting, Casting defects .Taguchi method .Statistical process control. Artificial neural network