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Throughout the casting process, mold filling plays a very significant role in the casting quality control. It is important to study the effect of gating system design on ingate velocity of the metal which affects the mechanical properties of casting. The effect of varying the design of four gating system elements namely pouring cup, sprue height, runner and ingate design on the multiple responses like tensile strength and percentage elongation is studied using a Taguchi’s L9 OA. The Taguchi technique was coupled with a Grey Relational Analysis (GRA) to obtain a Grey Relational Grade (GRG) for evaluating multiple responses. ANOVA has been applied to identify the significance of different parameters and it was found that the pouring cup design and the runner cross-section along its length collectively contributed above 76% of the total GRG value. Finally, the confirmation tests were performed to validate the predicted optimized results and it established an improvement of 9.90% from the initial design.
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