IAETSD JOURNAL FOR ADVANCED RESEARCH IN APPLIED SCIENCES, VOLUME 4, ISSUE 1, JAN-JUNE /2017

ISSN (ONLINE): 2394-8442

STUDY OF CHEMICAL BONDED MOULDING SAND WITH

COWDUNG AND BAGASSE AS ADDITIVE
Vinay Murgod1, Vinod Dayannavar2, Nikhil R3, Ganesh Chate4
[1, 2, 3, 4]
Department of Industrial and Production Engineering, Gogte Institute of Technology, Belagavi-590008, Karnataka, India
vmmurgod@git.edu

ABSTRACT.

Casting is the most basic manufacturing process, used to shape the metals. The quality of the casted
component is in turn dependent on sand mold properties .In this work ,Taguchi technique is used to get better
sand mould properties .Taguchi technique helps study effect of many factors (variables) on the desired quality
characteristics most economically. By studying the effect of individual factors on the results, the best factor
combination can be determined.

L9 orthogonal array was used to conduct the experiments the input parameters varied during experimentation
were amount of resin, hardener, setting time and additives such as Biogases and cow dung. The responses
measured were permeability and shear strength. ANOVA test were carried out to get significant factors for the
responses. The optimized levels obtained by analysis were validated by confirmation tests. Additives are the waste
and hence these wastes can be used to improve sand mould properties.

Keywords: Casting, Taguchi Technique, Bagasse, Cow dung, ANOVA.

1. INTRODUCTION
A suitable and workable material possessing high refractoriness in nature can be used for mould making. Thus, the mold making material can be
metallic or non-metallic [1]. For metallic category, the common materials are cast iron, mild steel and alloy steels. In the non-metallic group
molding sands, plaster of paris, graphite, silicon carbide and ceramics are included [2]. But, out of all, the molding sand is the most common
utilized non-metallic molding material because of its certain inherent properties namely refractoriness, chemical and thermal stability at higher
temperature, high permeability and workability along with good strength. Moreover, it is also highly cheap and easily available.

1.1. Clay Content Test

Amount of clay is determined by carrying out the clay content test in which clay in molding sand of 50 grams is defined as particles which when
suspended in water, fail to settle at the rate of one inch per min. Clay consists of particles less than 20 micron, per 0.0008 inch in diameter.

1.2. Grain Fineness Test

For carry out grain fineness test a sample of dry silica sand weighing 50 gms free from clay is placed on a top most sieve bearing U.S. series
equivalent number 6. A set of eleven sieves having U.S. Bureau of standard meshes 6, 12, 20, 30, 40, 50, 70, 100, 140, 200 and 270 are mounted
on a mechanical shaker [3]. The series are placed in order offineness from top to bottom. The free silica sand sample is shaked in a mechanical
shaker for about 15 minutes. After this weight of sand retained in each sieve is obtained sand and the retained sand in each sieve is multiplied by
2 which gives % of weight retained by each sieve [4]. The same is further multiplied by a multiplying factor and total product is obtained. It is
then divided by total % sand retained by different sieves which will give G.F.N

1.3. Taguchi Method

The technique of laying out the conditions of experiments involving multiple factors was first proposed by Englishman, Sir R.A.Fisher. The
method is popularly known as factorial design of experiments. A full factorial design will identify all possible combinations for a give set of
factors. Since most industrial experiments usually involve a significant number of factors, a full factorial design results in a large number of
experiments [5]. To reduce the number of experiments to a practical level, only a small set from all possibilities is selected. The method of
selecting a limited number of experiments which produces the most information is known as partial fraction experiment. Although this method is
well known, there are no general guidelines for its application or the analysis of the results obtained by performing the experiments. Taguchi
constructed a special set of general design guidelines for factorial experiments that cover many applications [3].

To Cite This Article: Vinay Murgod, Vinod Dayannavar, Nikhil R and Ganesh Chate,. STUDY OF CHEMICAL
BONDED MOULDING SAND WITH COWDUNG AND BAGASSE AS ADDITIVE. Journal for Advanced Research
in Applied Sciences ;Pages: 303-311
304. Vinay Murgod, Vinod Dayannavar, Nikhil R and Ganesh Chate,. STUDY OF CHEMICAL BONDED MOULDING
SAND WITH COWDUNG AND BAGASSE AS ADDITIVE. Journal for Advanced Research in Applied Sciences;
Pages: 303-311

1.4. Analysis of the S/N Ratio

Taguchi method uses the (signal to noise (S/N) ratio, because it minimizes quality characteristic variation due to uncontrollable parameter.
The hardness and impact energy is the objective function so that "the larger-the-better" S/N ratio is chosen. The S/N ratio used for this type of
response is given by [1, 4]. The S/N ratio for the larger-the-better is:

S/NLTB = -10log[MSD]

(1)

Where: n is the number of measurements in a trial/row, in this case, n=1 and y is the measured value in a run/row. The S/N ratio values
are calculated by taking into consideration equation. 1. The S/N ratio values obtained for this experiment are as shown in tables respectively.

1.5. Analysis of variance (ANOVA):

Analysis of Variance (ANOVA) is a computational technique to quantitatively estimate the relative contribution, which each controlled
parameter makes to the overall measured response and expressing it as a percentage. ANOVA uses the S/N ratio responses for these calculations.
The basic idea of ANOVA is that the total sum of squares of the standard deviation is equal to the sum of squares of the standard deviation
caused by each parameter. The total sum of squared deviations SS T from the total mean S/N ratio m can be calculated as [2,3]

(2)
Where n is the number of experiments in the orthogonal array and i is the mean S/N ratio for the ith experiment. The percentage contribution, P
of the process parameters on the hardness and impact energy (shown as table 8 and 9) can be calculated as:

(3)

2. PROBLEM DEFINITION
Through literature survey and research gap it has been found that Permeability and Shear Strength influence casting quality. From the data
obtained through literature survey and pilot experiments the following factors are taken into account at different levels and they are as shown.

Permeability increases when resin is at a higher level i.e. level 3 (22gm), and hardener at level 1 (0.4*22gm) equals to 8.8gm and
using Cow-dung as an additive at level 3.
Shear Strength increases when resin is at a higher level i.e. level 2 (22gms) and hardener at level 1 (0.4*22gm) equals to 8.8gm and
using Cow-dung as an additive.

3. METHODOLOGY
The experimental procedure flows according to the matrix shown below (L9 Orthogonal).

L9 (34) Orthogonal Array

Performance
Independent Variables Parameter Value

Experiment # Variable 1 Variable 2 Variable 3 Variable 4

1 1
2 1
3 1
4 2
5 2
6 2
7 3
8 3
9 3
Layout of L9 Orthogonal Array
1 1
2 2
3 3
1 2
2 3
3 1
1 3
2 1
3 2
1 P1
2 P2
3 P3
3 P4
1 P5
2 P6
2 P7
3 P8
1 P9
305. Vinay Murgod, Vinod Dayannavar, Nikhil R and Ganesh Chate,. STUDY OF CHEMICAL BONDED MOULDING
SAND WITH COWDUNG AND BAGASSE AS ADDITIVE. Journal for Advanced Research in Applied Sciences;
Pages: 303-311

3.1. Procedure to Obtain Bagasse and Cow Dung

For conduction of the experiment totally 15 Kg of no bake sand & 1 Ltr Part A resin & 0.5 Ltr a part B hardener is required. Around
200 gm of Cow dung & 50 gm of Bagasse is required Take around 5 Kg of crushed Sugarcanes put them under sunlight, So that they get dried to
maximum extent & moisture contents almost reaches zero. When assured of no moisture in the canes take around 250 gm into a mixing jar &
further crush it using a mixer. So that it turns to powder form. Repeat the procedure until we obtain 200 gm of dried & powdered Bagasse. Cow
dung is also obtained from the same above process as bagasse.

To conduct the experiments the following equipments are required

Sand Muller For mixing of sand with resin and hardener along with bagasse and cow dung and to ensure proper mixing of all four
components.
Standard rammer To obtain specified sized specimen on which further experiments can be carried out ( 5 cm & Height 5cm)
Universal strength testing machine To find the compression strength & shear strength of the prepared specimen)
Permeability meter To find the permeability number of the prepared specimen
Hardness tester To find the hardness number of the top & bottom surfaces of the prepared specimen

4. RESULTS AND DISCUSSIONS

4.1. Shear Strength

The results obtained after experimentation is discussed, analysis is done using Minitab 17 software package. The experiments are conducted
using L9 orthogonal Array (Table No 4.1 gives the results and discussion for Shear strength). The table no 4.1 gives the different levels that are
used for experimentation. These levels are selected on the basis of literature survey and industrial standards. It shows the three different of resin
to hardener weight ratio and the different ways in which the additives are taken and used. The percentage weight of additives to sand is as shown
below

Table 4.1 Levels of different factors

Level Resin percentage Hardener percentage Additives

(% wt of sand ) (%wt of resin)
1 1.8 0.4 No additives
2 2 0.5 Bagasse
3 2.2 0.6 Cow dung

Table no 4.2 is the Design of Experiments of the experimentations.

Table 4.2- Design Matrix for shear strength L9 Orthogonal Array

Resin Resin to hardener ratio Additives

1 1 1
1 2 2
1 3 3
2 1 2
2 2 3
2 3 1
3 1 3
3 2 1
3 3 2

For the readings of shear strength the similar experiments and testing are carried out. Three replicates are taken and their average value is shown
in the table no 4.3
Table 4.3- Average shear strength readings for the experiments

Resin Resin to hardener ratio Additives Average shear strength

1 1 1 280
1 2 2 80
1 3 3 160
2 1 2 740
2 2 3 750
2 3 1 280
3 1 3 690
3 2 1 530
3 3 2 850
306. Vinay Murgod, Vinod Dayannavar, Nikhil R and Ganesh Chate,. STUDY OF CHEMICAL BONDED MOULDING
SAND WITH COWDUNG AND BAGASSE AS ADDITIVE. Journal for Advanced Research in Applied Sciences;
Pages: 303-311

The table no 4.4 gives the Signal to noise ratio. Larger the better condition is taken. The signals to noise for obtained responses are generated
using Minitab software. The values are as shown in the table no 4.4.

Table 4.4- L9 Orthogonal with average shear strength and signal to noise ratio

Resin Resin to hardener ratio Additives Average shear strength SNRA1

1 1 1 280 48.94316
1 2 2 80 38.0618
1 3 3 160 44.0824
2 1 2 740 57.38463
2 2 3 750 57.50123
2 3 1 280 48.94316
3 1 3 690 56.77698
3 2 1 530 54.48552
3 3 2 850 58.58838

Analysis of variance for signal to noise ratio: The basic idea of ANOVA is that the total sum of squares of the standard deviation is equal to the
sum of squares of the standard deviation caused by each parameter.

Table 4.5 - Analysis of variance for signal to noise ratio

Source DF Seq SS Adj SS Adj MS F P

Resin 2 290.099 290.099 145.049 3.83 0.207
Resin to 2 33.884 33.884 16.942 0.45 0.691
hardener
Additives 2 6.371 6.371 3.186 0.08 0.922
Residual error 2 75.797 75.797 37.898
Total 8 406.151

Table 4.6: Response Table for Signal to Noise Ratios (Larger is better)

Level Resin Resin to hardener ratio Additives

1 43.70 54.37 50.79
2 54.61 50.02 51.34
3 56.62 50.54 52.79
Delta 12.92 4.35 2.00
Rank 1 2 3

Graph 4.1: Plot for signal to noise ratios

307. Vinay Murgod, Vinod Dayannavar, Nikhil R and Ganesh Chate,. STUDY OF CHEMICAL BONDED MOULDING
SAND WITH COWDUNG AND BAGASSE AS ADDITIVE. Journal for Advanced Research in Applied Sciences;
Pages: 303-311

From the above graph 4.1, it can be seen that the highest value of signal to noise ratio is for level 3 for resin and level 1 for resin to hardener
ratio and level 3 for additives

Table 4.7 for Analysis of Variance for Means

Source DF Seq SS Adj SS Adj MS F P
Resin 2 450.556 450.556 225.278 3.91 0.203
Resin to 2 33.756 33.756 16.878 0.29 0.773
Hardener
Additives 2 66.822 66.822 33.411 0.58 0.663
Residual 2 115.089 115.089 57.544
error
Total 8 666.222

Table 4.8: Response for Means

Level Resin Resin to hardener ratio Additives

1 173.3 570.0 363.3
2 590.0 453.3 556.3
3 690.0 430.0 533.3
Delta 516.7 140.0 193.3
Rank 1 3 2

Graph 4.2: Plots for Means

Hence to get good shear strength resin at level 3 (2.2% i.e.22gm), hardener at level 1 (0.4% of 22gm i.e. 8.8 gm) and additives at level 3 (cow
dung i.e.0.03 % wt of sand =30 gm) has to be kept to get good permeability of the mold.

4.1.2. Confirmation Test

A confirmation test is performed for shear strength by setting Resin at level 3, Hardener at level 1 and additives at level 3.The table no 4.9 shows
the values obtained by above process parameter settings

Table 4.9: Shear Strength values.

S.No Shear Strength

1 678
2 696
3 668
4 695

4.2. Permeability

In this chapter the results obtained after experimentation is discussed, analysis is done using Minitab 17 software package. The experiments are
conducted using L9 orthogonal Array (Table No 4.10 gives the results and discussion for permeability).
308. Vinay Murgod, Vinod Dayannavar, Nikhil R and Ganesh Chate,. STUDY OF CHEMICAL BONDED MOULDING
SAND WITH COWDUNG AND BAGASSE AS ADDITIVE. Journal for Advanced Research in Applied Sciences;
Pages: 303-311

Permeability is the ability of the mold to allow the gases generated to pass through it. If the permeability is less, blow holes will occur,
hence in this section an effort is made to optimize process parameters such that high permeability is obtained.

The table 4.10 gives the different levels that are used for experimentation. These levels are selected on the basis of literature survey and
industrial standards. It shows the three different of resin to hardener weight ratio and the different ways in which the additives are taken and
used. The percentage weight of additives to sand is as shown below in table 4.10

Table 4.10 Levels of different factors

Level Resin percentage Hardener percentage Additives

(% wt of sand ) (%wt of resin)

1 1.8 0.4 No additives

2 2 0.5 Bagasse
3 2.2 0.6 Cow dung

Table No 4.11 is the Design of Experiments of the experimentations.

Table 4.11- Design Matrix for permeability L9 Orthogonal Array

Resin Resin to hardener ratio Additives

1 1 1
1 2 2
1 3 3
2 1 2
2 2 3
2 3 1
3 1 3
3 2 1
3 3 2

For the readings of permeability the similar experiments and testing are carried out. Three replicates are taken and average value is shown in
Table no 4.12

Table 4.12- Average permeability reading for the experiment

Resin Resin to Hardener Ratio Additives Average Permeability

1 1 1 190

1 2 2 170

1 3 3 210

2 1 2 305

2 2 3 290

2 3 1 195

3 1 3 370

3 2 1 250

3 3 2 360

The below table gives the Signal to noise ratio. Larger the better condition is taken .The signal to noise for obtained responses are generated
using Minitab software. The values are as shown in table no 4.13
309. Vinay Murgod, Vinod Dayannavar, Nikhil R and Ganesh Chate,. STUDY OF CHEMICAL BONDED MOULDING
SAND WITH COWDUNG AND BAGASSE AS ADDITIVE. Journal for Advanced Research in Applied Sciences;
Pages: 303-311

Table 4.13- L9 Orthogonal with average permeability and signal to noise ratio

Resin Resin to Hardener Ratio Additives Permeability SNRA1

1 1 1 190 45.57507
1 2 2 170 44.60898
1 3 3 210 46.44439
2 1 2 305 49.686
2 2 3 290 49.24796
2 3 1 195 45.80069
3 1 3 370 51.36403
3 2 1 250 47.9588
3 3 2 360 51.12605

Analysis of variance for signal to noise ratio: The basic idea of ANOVA is that the total sum of squares of the standard deviation is equal to the
sum of squares of the standard deviation caused by each parameter.

Table 4.14-Analysis of variance for signal to noise ratio

Source DF Seq SS Adj SS Adj MS F P

Resin 2 32.152 32.152 16.076 11.02 0.083
Resin to 2 4.015 4.015 2.008 1.78 0.421
Hardener
Additives 2 11.038 11.038 5.519 3.78 0.209
Residual 2 2.917 2.917 1.459
Total 8 50.123

Table 4.15- Response table for signal to noise ratio.(larger is better)

Level Resin Resin to hardener Additives

1 45.54 48.88 46.44
2 48.32 47.27 48.47
3 50.15 49.02 49.02
Delta 4.61 1.60 2.57
Rank 1 3 2

R-SQ = 94.2%.
R-SQ (Adj) =76.7%.

Graph 4.3: Plots for signal to noise ratios

310. Vinay Murgod, Vinod Dayannavar, Nikhil R and Ganesh Chate,. STUDY OF CHEMICAL BONDED MOULDING
SAND WITH COWDUNG AND BAGASSE AS ADDITIVE. Journal for Advanced Research in Applied Sciences;
Pages: 303-311

From the above graph 4.3, it can be seen that the highest value of signal to noise ratio is for level 3 for resin and level 1 for resin to hardener
ratio and level 3 for additives. Analysis for variance for means: From the below table, using ANOVA it can be seen that resin has most effective
contribution and resin to hardener has least contribution for responses. Resin is most significant affecting factor.

Table 4.16 Analysis of variance for means

Source DF SEQ SS Adj SS Adj MS F P

Resin 2 28067 28067 14033.3 14.39 0.065
Resin to 2 4117 4117 2058.3 2.11 0.321
Hardener
Additives 2 10717 10717 5358.3 5.50 0.154
Residual Error 2 1950 1950 975
Total 8 44850

Table 4.17 Response table for means

Level Resin Resin to hardener Additives

1 190.0 288.3 211.7
2 263.3 236.7 278.3
3 326.7 255.0 290.0
Delta 136.7 51.7 78.3
Rank 1 3 2

Hence for getting good permeability resin at level 3 (2.2% i.e.22gm), hardener at level 1 (0.4% of 22gm i.e. 8.8 gm) and additives at level 3
(cow dung i.e.0.03 % wt of sand =30 gm) has to be kept to get good permeability of the mold.

4.2.1 Confirmation Test

A confirmation test is performed for permeability by setting Resin at level 3, Hardener at level 1 and additives at level 3.The below table shows
the values obtained by above process parameter settings.

Table 4.18: Permeability Values

S.No Permeability
1 380
2 378
3 364
4 355

4. CONCLUSION
Aim of the experiment is to get process parameters for making molds of cores in the Foundry using Phenol-formal-Dehyde as resin. The
experiments are conducted and analyzed by using Taguchi technique. From the Results and Discussion it has been found that:

Permeability increases when resin is at a higher level i.e. level 3 (22gm), and hardener at level 1 (0.4*22gm) equals to 8.8gm and using
Cow-dung as an additive at level 3.

Shear Strength increases when resin is at a higher level i.e. level 2 (22gms) and hardener at level 1 (0.4*22gm) equals to 8.8gm and
using Cow-dung as an additive.
Hence the validations of the obtained results are confirmed by confirmation tests. The optimized levels can be set for Foundry process.

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[3]Guharaja G, Optimization of Green Sand Casting Process by using Taguchis method, McGraw Hill, New York, 65-75, 2006.

[4]A. P. MoreReview of Casting Defect Analysis to Initiate the Improvement Process.

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SAND WITH COWDUNG AND BAGASSE AS ADDITIVE. Journal for Advanced Research in Applied Sciences;
Pages: 303-311

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