ARBAMINCH INSTITUTE OF TECHNOLOGY FACULITY OF MECHANICAL ENGINEERING

Abstract

In the manufacturing industry, the selection of appropriate casting methods is crucial for ensuring the production of high-quality components that meet evolving market demands. However, the Akaki Basic Metal Factory in Ethiopia, which manufactures products at a large capacity, has faced limitations in production efficiency, quality standards, and market competitiveness when using traditional sand casting methods. Currently, ABMI utilizes sand casting as its primary production method, but the company faces several challenges with this approach, including inconsistent mold preparation, variations in dimensional accuracy and surface finish, and high defect rates of 16.8% to 19.4%. These quality-related issues have resulted in lower performance and financial losses for ABMI. The study aims to assess whether transitioning to permanent mold casting can address the shortcomings of traditional sand casting. Permanent mold casting is widely recognized for its ability to improve product quality, increase efficiency, and enhance cost-effectiveness. The investigation evaluates the technical, economic, and operational factors involved in adopting this casting technique. The findings indicate that permanent mold casting has the potential to significantly reduce defect rates, in sand casting down to 2-5%. It can also decrease workflow by eliminating pattern making, core making, and mold making steps, leading to improved dimensional accuracy, surface finish, and overall product quality. Furthermore, permanent mold casting offers the benefits of reduced waste, energy consumption, and enhanced eco-friendliness Based on the analysis, the study provides ABMI with recommendations for the successful implementation of permanent mold casting. The transition has the potential to help the company address its current challenges, improve productivity and efficiency, and enhance its overall competitiveness in the market