Open Access Open Access  Restricted Access Subscription or Fee Access

Linear Modeling of Quartz-based Resin Bonded Sand Mould System Using Design of Experiments

B. Surekha, B.P. Kishore, A.A. Kumar, B.N. Mahesh, B.U. Lakshmi, V.R.K. Rao

Abstract


The resin bonded core process is the room-temperature core making process made of sand and binder mixture accelerated by a catalyst. The quality of the cast products that are produced utilizing quartz sand-based resin bonded sand moulds largely depends on the mould properties, namely compression, shear and tensile strengths and permeability which depend on the input parameters. The relationship of these properties with the input parameters, such as percentages of resin and catalyst, number of strokes and curing time, etc,. are complex in nature. Full factorial design of experiments is used to establish the linear relationship between the said inputs and outputs. Main effects plots has been used to study the effect of amounts of resin and catalyst, number of strokes and curing time on compression, tensile and shear strengths, and permeability of the quartz sand-based resin bonded sand mould system. Analysis of Variance (ANOVA) has been performed to test statistical adequacy of the models. Twenty random test cases have been considered to test and compare their performances. It has been observed that the developed models are found to predict the responses of the resin bonded sand mould system with reasonably good accuracy.

Keywords


Quartz Sand, Resin Bond, Design of Experiments, Analysis of Variance

Full Text:

PDF

References


D. Sitaramaiah, R.L. Kumar and A.K. Kar, Some experiments on cold setting organic binders, The British Foundryman, Vol. 63, pp. 30-34, 1970.

J. Robins, L.I. Toriello and J. Hamilton, A new phenolic-urethane nobake binder, AFS Transactions, Vol. 79, pp. 105-114, 1971.

D.M. Trinowski, New Cold box Bimder System for improved Productivity, AFS Transactions, Vol. 107, pp. 51-57, 1999.

Y. Chang and H. Hocheng, The flowability of bentonite bonded green moulding sand, Journal of Materials Processing Technology, Vol. 113, pp. 238-244, 2001.

B. Sirrell, M. Holiday and J. Campbell, Benchmark testing the flow and solidification modeling of AL castings, JOM, The Member Journal of TMS, Vol. 48, No. 3, pp. 20-23, 1996.

S.I. Bakhtiyarov and R.A. Overfelt, CFD modeling and experimental study of resin bonded sand/air two phase flow in sand core making process, Power Technology, Vol. 133, No. 1-3, pp. 68-78, 2003.

S.K. Shaha, M.M. Haque and M. Hassan, Simulation of casting solidification and its verification on structure and property of Fe-C-Al cast iron, The Third Int. Conf. on Structure, Processing and Properties of Materials, Dhaka, Bangladesh, 24-26 Feb 2010.

S.K. Shaha and M.M. Haque, Simulation of heat flow in computational method and its verification on the structure and property of grey cast iron, American Journal of Applied Sciences, Vol. 7, No.6, pp. 795-799, 2010.

Douglas C. Montgomery, Design and Analysis of Experiments, Fifth Edition, John Wiley & Sons, Inc, 2001.

B.K. Dhindaw, M. Chakraborty, Study and control of properties and behaviour of different sand systems by application of statistical design of experiments, Proc. of 41st International Foundry Congress, Belgique, pp. 9-14, 1974.

R.R. Kundu and B.N. Lahiri, Study and statistical modeling of green sand mould properties using RSM, International Journal of Materials and Product Technology, Vol. 31, pp. 143-158, 2008.

M.B. Parappagoudar, D.K. Pratihar and G.L. Datta, Non-linear modeling using central composite design to predict green sand mould properties, Proc. Of IMech E, Part B: Journal of Engineering Manufacture, Vol. 221, pp. 881-895, 2007.

M.B. Parappagoudar, D.K. Pratihar and G.L. Datta, Linear and non-linear modeling of cement bonded sand moulding system using conventional statistical regression analysis, Journal of Materials Engineering and performance, Vol. 17, pp. 472-481, 2008.


Refbacks

  • There are currently no refbacks.


Creative Commons License
This work is licensed under a Creative Commons Attribution 3.0 License.