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<p>The sand-coated iron mold casting of ductile iron crankshafts requires balancing several interdependent quality-related factors rather than controlling a single parameter. In this work, numerical simulations using a commercial casting simulation software were conducted according to an orthogonal experimental design, and the simulation results were evaluated using a multi-attribute decision-making (MADM) approach to construct an overall quality index (OQI) that simultaneously reflects shrinkage porosity (VSP) and pearlite lamellar spacing (PLS). The process parameters examined included sand coating thickness, pouring temperature, pouring time, and the preheating temperature of both the mold and the coating. Based on the OQI evaluation, the optimal process conditions were identified as a pouring temperature of 1375&#xa0;°C, filling time of 20&#xa0;s, mold preheating temperature of 160&#xa0;°C, and a sand coating thickness of 7&#xa0;mm. Under these conditions, the corresponding microstructure evolution and shrinkage behavior were first predicted through simulation, and crankshaft specimens cast with the optimized parameters were then examined experimentally. The simulated and experimental results for nodularity, graphite morphology (including nodule size and count), and pearlite lamellar spacing showed good agreement, with deviations remaining within the expected experimental error. In addition, the differences between the simulated and measured tensile strength and elongation were also within the expected experimental error range. These results indicate a high level of consistency between simulation and experiment, confirming the reliability of the proposed integrated optimization method for improving the casting quality of sand-coated iron mold ductile iron crankshafts.</p> Graphical Abstract <p></p>

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Multi-objective Optimization of Shrinkage Porosity and Pearlite Lamellar Spacing in Sand-Coated Iron Mold Ductile Iron Crankshafts Using Orthogonal Design-Based Modeling Simulation and MADM

  • 期刊论文

  • 发表日期：

    2026年1月29日

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  • Kunxian Luo,
  • Dehong Lu,
  • Cuijuan Li,
  • Jingwen Li,
  • Keze Zheng

摘要

The sand-coated iron mold casting of ductile iron crankshafts requires balancing several interdependent quality-related factors rather than controlling a single parameter. In this work, numerical simulations using a commercial casting simulation software were conducted according to an orthogonal experimental design, and the simulation results were evaluated using a multi-attribute decision-making (MADM) approach to construct an overall quality index (OQI) that simultaneously reflects shrinkage porosity (VSP) and pearlite lamellar spacing (PLS). The process parameters examined included sand coating thickness, pouring temperature, pouring time, and the preheating temperature of both the mold and the coating. Based on the OQI evaluation, the optimal process conditions were identified as a pouring temperature of 1375 °C, filling time of 20 s, mold preheating temperature of 160 °C, and a sand coating thickness of 7 mm. Under these conditions, the corresponding microstructure evolution and shrinkage behavior were first predicted through simulation, and crankshaft specimens cast with the optimized parameters were then examined experimentally. The simulated and experimental results for nodularity, graphite morphology (including nodule size and count), and pearlite lamellar spacing showed good agreement, with deviations remaining within the expected experimental error. In addition, the differences between the simulated and measured tensile strength and elongation were also within the expected experimental error range. These results indicate a high level of consistency between simulation and experiment, confirming the reliability of the proposed integrated optimization method for improving the casting quality of sand-coated iron mold ductile iron crankshafts.

Graphical Abstract