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

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Optimization of Manufacturing Processes

Part of the book series: Springer Series in Advanced Manufacturing ((SSAM))

Abstract

The traditional trial-and error method applied to derive empirical relation and optimize the process is time consuming and results in reduced productivity, high rejection and cost. Hence, current research in foundries focussed towards development of statistical modelling and optimization tools. The present research work is focused on modelling and optimization of Alpha-set moulding sand system. The variables such as percent of resin and hardener, and curing time will influence the sand mould properties, namely, compression strength, permeability, mould hardness, gas evolution and collapsibility. Experimental data is collected as per CCD design matrix and non-linear models have been developed for all responses. The behaviour of all responses is studied by utilizing surface plots. The statistical adequacy of all models is tested with help of ANOVA. All responses are tested for their prediction capacity with the help of test cases. The predictive non-linear models, developed for the process resulted in average deviation of less than 5%. The optimization (GA, PSO, DFA and TLBO) tools are applied to optimize the process for conflicting requirements in sand mould properties. Six case studies with different combination of weight fractions assigned to sand mould properties are considered. The optimum solution correspond to highest composite desirability value is selected. TLBO outperformed other optimization tools (i.e. GA, PSO, and DFA) while determining the highest desirability value and resulted in optimized sand mould properties. Experiments are conducted for the optimized and normal (i.e. lowest desirability) sand mould conditions. Castings are prepared by pouring molten LM20 alloy to the prepared moulds. The casting obtained for the optimized sand mould condition resulted in a better casting quality.

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Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, PES Institute of Technology and Management, Shivamogga, 577204, Karnataka, India

    G. C. Manjunath Patel

  2. Department of Industrial and Production Engineering, K.L.S. Gogte Institute of Technology, Belgaum, India

    Ganesh R. Chate

  3. Department of Mechanical Engineering, Padre Conceicao College of Engineering, Verna, Goa, India

    Mahesh B. Parappagoudar

Authors
  1. G. C. Manjunath Patel
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  2. Ganesh R. Chate
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  3. Mahesh B. Parappagoudar
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Corresponding author

Correspondence to G. C. Manjunath Patel .

Editor information

Editors and Affiliations

  1. Department of Mechanical and Industrial Engineering Technology, University of Johannesburg, Doornfontein, Johannesburg, South Africa

    Kapil Gupta

  2. Assistant Professor, University Center for Research and Development, Chandigarh University, Gharuan, Mohali, India

    Munish Kumar Gupta

Appendices

Appendix 1: Test Case Data for Sand Moulding Variables and Moulding Sand Properties

Test no.

Moulding sand variables

Moulding sand properties

% of resin

% of hardener

Curing time

CS, KPa

P

MH

CP, KPa

GE, ml/gm

1

1.85

0.20

064

212.4

187.3

62.04

142.2

8.40

2

2.20

0.25

118

376.8

138.6

76.74

256.8

8.34

3

1.90

0.30

106

360.7

134.3

73.28

258.9

7.82

4

1.95

0.35

074

367.3

120.2

71.20

256.3

7.73

5

1.80

0.35

089

271.8

159.9

72.48

216.0

8.02

6

2.10

0.30

102

414.0

108.4

79.84

290.4

8.72

7

1.95

0.25

096

332.2

142.8

76.23

260.6

8.21

8

2.20

0.40

063

381.6

100.7

74.03

286.7

9.45

9

2.15

0.20

074

361.1

121.3

75.32

292.4

9.20

10

2.05

0.35

096

428.8

99.8

78.13

289.7

8.63

11

1.85

0.30

088

276.3

164.3

72.38

218.9

8.04

12

2.20

0.25

112

350.8

132.4

75.30

280.1

8.80

13

1.80

0.25

092

247.8

182.7

65.23

151.5

8.38

14

2.05

0.35

078

402.5

101.4

76.40

278.7

8.08

Appendix 2: Summary Results of Model Predicted Test Cases of Sand Mould Properties (CS, P, MH, GE and CP)

Test no.

Compression strength, KPa

Permeability

Exp. value

Model prediction

Deviation (%)

Absolute deviation (%)

Exp. value

Model prediction

Deviation (%)

Absolute deviation (%)

1

212.4

225.17

−6.01

−6.01

187.3

178.10

4.91

4.91

2

376.8

355.63

5.62

5.62

138.6

134.00

3.32

3.32

3

360.7

342.85

4.95

4.95

134.3

137.19

−2.15

2.15

4

367.3

356.35

2.98

2.98

120.2

124.92

−3.93

3.93

5

271.8

282.86

−4.07

−4.07

159.9

157.17

1.71

1.71

6

414.0

389.05

6.03

6.03

108.4

115.54

−6.59

6.59

7

332.2

343.86

−3.51

−3.51

142.8

135.50

5.11

5.11

8

381.6

390.71

−2.39

−2.39

100.7

106.22

−5.48

5.48

9

361.1

374.83

−3.80

−3.80

121.3

114.94

5.24

5.24

10

428.8

401.94

6.26

6.26

99.8

107.21

−7.43

7.43

11

276.3

294.49

−6.58

−6.58

164.3

154.15

6.18

6.18

12

350.8

360.63

−2.80

−2.80

132.4

130.08

1.75

1.75

13

247.8

239.59

3.31

3.31

182.7

178.71

2.18

2.18

14

402.5

391.30

2.78

2.78

101.4

109.90

−8.38

8.38

 

Mould hardness

Collapsibility

1

62.04

64.69

−4.27

4.27

142.2

155.8

−9.53

9.53

2

76.74

75.92

1.06

1.06

256.8

267.1

−4.02

4.02

3

73.28

74.88

−2.18

2.18

258.9

252.3

2.56

2.56

4

71.20

73.98

−3.91

3.91

256.3

272.5

−6.33

6.33

5

72.48

71.16

1.82

1.82

216.0

204.5

5.34

5.34

6

79.84

77.21

3.29

3.29

290.4

296.2

−2.01

2.01

7

76.23

74.05

2.86

2.86

260.6

254.5

2.34

2.34

8

74.03

74.40

−0.50

0.50

286.7

292.5

−2.03

2.03

9

75.32

74.40

1.22

1.22

292.4

290.4

0.67

0.67

10

78.13

77.23

1.15

1.15

289.7

308.5

−6.47

6.47

11

72.38

71.68

0.97

0.97

218.9

212.7

2.84

2.84

12

75.30

76.08

−1.03

1.03

280.1

271.7

2.98

2.98

13

65.23

68.40

−4.87

4.87

151.5

158.3

−4.48

4.48

14

76.40

76.01

0.52

0.52

278.7

300.8

−7.94

7.94

Appendix 3: Summary Results of the Test Cases for the Responses—GE

Test no.

Exp. value

Model prediction

Deviation (%)

Absolute deviation (%)

1

8.40

8.52

−1.37

1.37

2

8.34

8.16

2.12

2.12

3

7.82

8.14

−4.05

4.05

4

7.73

7.70

0.41

0.41

5

8.02

8.13

−1.34

1.34

6

8.72

8.38

3.88

3.88

7

8.21

8.33

−1.43

1.43

8

9.45

9.11

3.60

3.60

9

9.20

8.97

2.55

2.55

10

8.63

8.43

2.35

2.35

11

8.04

8.15

−1.36

1.36

12

8.80

8.42

4.29

4.29

13

8.38

8.72

−4.04

4.04

14

8.08

8.18

−1.27

1.27

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Manjunath Patel, G.C., Chate, G.R., Parappagoudar, M.B. (2020). Modelling and Optimization of Alpha-set Sand Moulding System Using Statistical Design of Experiments and Evolutionary Algorithms. In: Gupta, K., Gupta, M. (eds) Optimization of Manufacturing Processes. Springer Series in Advanced Manufacturing. Springer, Cham. https://doi.org/10.1007/978-3-030-19638-7_1

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  • DOI: https://doi.org/10.1007/978-3-030-19638-7_1

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