Optimization of Sand Casting Process Parameters to Minimize Cold Shut Defect

The quality of cast components is critical in manufacturing industries, as defects such as cold shuts lead to increased rejection rates, material waste, and production costs. This study employs Response Surface Methodology (RSM) to optimize key sand casting process parameters — pouring temperature, pouring time, moisture content, and mold hardness — in order to minimize cold shut defects. A Central Composite Design (CCD) was used to analyze parameter interactions and determine the optimal settings. The regression model demonstrated strong predictive accuracy with an R 2 value of 86.03%, while Analysis of Variance (ANOVA) confirmed the statistical significance of the results. Experimental validation showed a 45% reduction in cold shut defects. These findings highlight RSMs effectiveness as a robust tool for process optimization and quality improvement in casting operations, offering a practical framework for defect reduction and enhanced productivity in industrial applications.