Modeling and optimization of furan molding sand system using design of experiments and particle swarm optimization

Chate, Ganesh R.; Patel, Manjunath; Deshpande, Amruta; Parappagoudar, Mahesh B.

doi:10.1177/0954408917728636

Cited by 23 publications

(16 citation statements)

References 21 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Currently, the binders based on furfuryl resins constitute the largest group (approx. 55%) of binders used in no-bake moulding sands hardened without heating [Chate et al 2017;Acharya et al 2016].…”

Section: Journal Of Ecological Engineeringmentioning

confidence: 99%

Preliminary Tests of Innovative Eco-Friendly Furfuryl Resins and Foundry Sand Mixtures Based on These Resins

Kamińska¹,

Puzio²,

Angrecki³

et al. 2019

J. Ecol. Eng.

View full text Add to dashboard Cite

The foundry industry in Poland and EU member states is growing steadily. The alloys based on ferrous metals (cast steel and cast iron) largely contribute to this upward trend. Currently, foundries are facing the problem of increasing requirements, which enforce the production of castings characterized by high dimensional accuracy and surface smoothness with parallel elimination of casting defects. Castings are mostly made in moulding sand mixtures, which are also subject to more and more stringent requirements to meet the above-mentioned casting acceptance conditions. Additionally, moulding sands should ensure adequate mould stiffness to avoid the risk of dimensional deformations during the pouring of liquid metal to this mould and casting solidification. For these reasons, the production of this type of castings has been dominated by loose self-hardening sands with furfuryl resin, commonly called furan sands. In the group of self-hardening sands with synthetic resins, loose self-hardening sands with furfuryl resin enjoy the greatest popularity. What accounts for this fact is the high level of the reclamability of these sands, the possibility of obtaining castings with high dimensional accuracy, the ability to make intricate moulds and cores, the binding process taking place at ambient temperature, and low content of binder. Unfortunately, this technology also has some disadvantages, which include short lifetime of the sand mixture, harmful gases emitted from the sand, and currently also high cost of the sand mixture. The anticipated tightening of the environmental protection regulations in the EU countries, including limiting the content of free furfuryl alcohol in resins (<25% by mass) and reducing the emission of furfuryl alcohol, formaldehyde and BTEX compounds at workplaces, necessitated the development of a new generation of furfuryl resins friendly to the environment. The article compares the results of testing the strength properties of foundry moulding sands using two types of resins, i.e. the resin of a new generation synthesized by Grupa Azoty JRCh and a commercial resin used in the foundry industry. Additionally, derivatographic studies of the above mentioned sand mixtures were conducted, and the loss on ignition and the amount of gases emitted by the sand mixture were determined. Melting was also carried out to study the impact of the resin used on the surface quality of iron castings.

show abstract

Section: Journal Of Ecological Engineeringmentioning

confidence: 99%

Preliminary Tests of Innovative Eco-Friendly Furfuryl Resins and Foundry Sand Mixtures Based on These Resins

Kamińska¹,

Puzio²,

Angrecki³

et al. 2019

J. Ecol. Eng.

View full text Add to dashboard Cite

show abstract

“…Mould hardness (MH) and compression strength were found to have similar effects with moulding sand variables (i.e. grain fineness number, setting time, per cent of resin and hardener) [15]. The impact of different proportions of resin and hardener on the moulding strength was studied [15].…”

Section: Introductionmentioning

confidence: 99%

“…grain fineness number, setting time, per cent of resin and hardener) [15]. The impact of different proportions of resin and hardener on the moulding strength was studied [15]. Higher combination of resin and hardener had improved the moulding strength, but resulted in poor collapsibility and reduced permeability.…”

Section: Introductionmentioning

confidence: 99%

“…The good casting surface features with low-dimensional accuracy and mould collapsibility were obtained for the optimized binder composition [16]. Sufficient amount of curing time is always desirable for the hardener to undergo polymerization reaction that will develop strong bonding between the molecules of resin with silica sand grains [15]. The size, shape and size distribution of sand particles would control the mould permeability (i.e.…”

Section: Introductionmentioning

confidence: 99%

“…The response equation derived based on linear and nonlinear models were found capable of predicting the sand mould properties with reasonable accuracy. The effect of furan sand moulding parameters (grain fineness number, resin, hardener and setting time) on different properties of sand mould properties was studied [15]. The major problem addressed in furan sand mould system was poor collapsibility that resulted in hot tear in the castings.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Comprehensive modelling, analysis and optimization of furan resin-based moulding sand system with sawdust as an additive

Chate¹,

Patel

Bhushan

et al. 2019

J Braz. Soc. Mech. Sci. Eng.

View full text Add to dashboard Cite

Scarcity of high-cost silica sand, casting defect such as hot tear in hard moulds and casting ejection problem after solidification are the key industrial problems. Sawdust is a by-product of wood working industries, and economic disposal of sawdust in these industries is a growing concern to the wood industries. The present work utilized sawdust as an additive in preparing mould cavity for casting applications. Sand mould properties such as compression strength (CS), mould hardness (MH), gas evolution (GE), permeability (P) and collapsibility (CP) will have good impact on the quality of castings. The effect of variables, namely quantity of resin, hardener, sawdust and setting time, on no-bake furan-bonded sand system is studied in the present research work. The experiments are conducted as per design of experiments, and the data are used to investigate the effect of individual and combined parametric contributions towards responses and establish nonlinear input-output relationships. All nonlinear regression models (that is, input-output relationships) are found to be statistically adequate. The input-output relations are analysed and presented for each of the response with the help of surface plots. Further, the models are found to predict the output close to the experiment (target value). The grand average value in predicting responses is found to be equal to 5.03%. The multi-objective optimization of responses with conflicting nature (minimize: GE and CP; maximize: CS, P and MH) is carried out with the help of global fitness function values determined using genetic algorithm, particle swarm optimization, teacher-learner-based optimization and JAYA algorithms. The optimized values of process parameters that resulted in best set of responses are found to be equal to 60 min, 2.01%, 0.6% and 0.93% for setting time, quantity of resin, hardener and sawdust, respectively. Two automobile coupling parts are cast by pouring molten aluminium into the mould cavity with the optimized and non-optimum sand mould conditions. Further, these two cast components are tested for their quality characteristics, such as surface finish, yield strength, hardness, density and secondary dendrite arm spacing. It has been observed that the quality characteristics of castings produced in mould with optimized parameters are found to be much better.

show abstract

Modelling and Optimization of Alpha-set Sand Moulding System Using Statistical Design of Experiments and Evolutionary Algorithms

Patel

Chate²,

Parappagoudar³

2019

Springer Series in Advanced Manufacturing

View full text Add to dashboard Cite

Modeling and optimization of furan molding sand system using design of experiments and particle swarm optimization

Cited by 23 publications

References 21 publications

Preliminary Tests of Innovative Eco-Friendly Furfuryl Resins and Foundry Sand Mixtures Based on These Resins

Preliminary Tests of Innovative Eco-Friendly Furfuryl Resins and Foundry Sand Mixtures Based on These Resins

Comprehensive modelling, analysis and optimization of furan resin-based moulding sand system with sawdust as an additive

Modelling and Optimization of Alpha-set Sand Moulding System Using Statistical Design of Experiments and Evolutionary Algorithms

Contact Info

Product

Resources

About