Sustainable Modelling and Optimization of Aluminium Sand-Casting Process Parameters Using RSM, ANN and Fuzzy Logic

Metal casting process can produce complex shape products; however, it is usually time consuming and has poor product quality due to casting defects which also impact sustainability. To overcome this problem, in this research article, different techniques have been employed for Modelling of the process parameters during aluminium sand casting for improving process efficiency and sustainability. Moreover, Analysis of variance (ANOVA) test has also been carried out to identify the significant process parameters. Thereafter, RSM, ANN and FL models are developed to predict the percentage casting defects. The four important casting processes are used as input for ANN, FL models based on 27 Box-Behnken based experimental designs. The comparison of predicted values found that the ANN model is the most efficient in terms of accuracy achieved, contributing to enhanced sustainability through reduced time, cost, and defects in the process. Based on results, ANN model is found more suitable as compared to others for the entire range of process parameters.