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Impact of the Different Moulding Parameters on Properties of the Green Sand Mould

Dheya Abdulamer
Archives of Foundry Engineering | 2023 | vol. 23 | No 2 | 5-9 | DOI: 10.24425/afe.2023.144288
Keywords Green sand Compactability Tensile strength Permeability Taguchi method
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Abstract

Sand Casting process depends mainly on properties of the green sand mould, sand casting requires requires producing green sand mould without failure and breakage during separation the mould from the model, transportation and handling. Production of the green sand mould corresponding to dimensions and form of the desired model without troubles depends on the properties of the green sand. Ratio of constituents, preparation method of the green sand, mixing and pressing processes determine properties of green sand. In the present work, study effect of the moulding parameters of bentonite content, mixing time, and compactability percentage on the properties of the green sand mould have been investigated. Design of experiments through Taguchi method was used to evaluate properties of permeability, compressive strength, and tensile strength of the green sand. It was found that 47% of compactability, 9(min) of mixing time, and 6% of bentonite content gives highest values of these properties simultaneously.
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Authors and Affiliations

Dheya Abdulamer
1
ORCID: ORCID
  1. University of Technology, Iraq

Optimizing Sand Moulding Process through Regression Models and Destructive Testing

Dheya Abdulamer
Archives of Foundry Engineering | 2023 | vol. 23 | No 4 | 163-168 | DOI: 10.24425/afe.2023.148959
Keywords Green sand mould Moulding parameters design of experiments Destructive tests regression methods
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Abstract

The main objective of the present study is enhanced of the sand moulding process through addressing the sand mould defects and failures, ultimately lead to improve production of the sand castings with well-defined of pattern profiles. The research aimed to reduce the cost and energy expenditure associated with the compaction time of the sand moulding process. Practical destructive tests were conducted to assess properties of the green sand moulds. Linear regression and multi-regression methods were employed to identify the key factors influencing the sand moulding process. The proposed experimental destructive tests and predicted regression methods facilitated measurement of the green sand properties and enabled evaluation of the effective moulding parameters, thereby enhancing the sand moulding process. Factorial design of experiments approach was employed to evaluate effect of parameters of water content and mixing time of the green sand compaction process on the mechanical properties of green sand mould namely the tensile strength, and compressive strength.
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Bibliography

[1] Abdulamer, D. & Kadauw, A. (2019). Development of mathematical relationships for calculating material-dependent flowability of green molding sand. Journal of Materials Engineering and Performance. 28(7), 3994-4001. DOI: https://doi.org/10.1007/s11665-019-04089-w.
[2] Shahria, S., Tariquzzaman, M., Rahman, H., Al Amin, M., & Rahman, A. (2017). Optimization of molding sand composition for casting Al alloy. International Journal of Mechanical Engineering and Applications. 5(3), 155-161. DOI:10.11648/j.ijmea.20170503.13.
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[9] Abdulamer, D. (2023). Impact of the different moulding parameters on engineering properties of the green sand mould. Archives of Foundry. 23(2), 5-9. DOI: 10.24425/afe.2023.144288.
[10] Kumar, S. Satsangi, P. & Prajapati, D. (2011). Optimization of green sand casting process parameters of a foundry by using taguchi’s method. International Journal of Advanced Manufacturing Technology. 55(1-4), 23-34. DOI: 10.1007/s00170-010-3029-0.
[11] Murguía, P. Ángel, R. Villa González del Pino, E. Villa, Y. & Hernández del Sol, J. (2016). Quality improvement of a casting process using design of experiments. Prospectiva. 14(1), 47-53. DOI: 10.15665/rp.v14i1.648.
[12] Abdullah, A. Sulaiman, S. Baharudin, B. Arifin, M. & Vijayaram, T. (2012). Testing for green compression strength and permeability properties on the tailing sand samples gathered from ex tin mines in perak state, Malaysia. Advanced Materials Research. 445, 859-864. DOI: 10.4028/www.scientific.net/AMR.445.859.
[13] Abdulamer, D. (2021). Investigation of flowability of the green sand mould by remote control of portable flowability sensor. Archives of Materials Science and Engineering, 112(2), 70-76. DOI: 10.5604/01.3001.0015.6289.
[14] Bast, J., Simon, W. & Abdullah, E. (2010). Investigation of cogs defects reason in green sand moulds. Archives of Metallurgy and Materials. 55(3), 749-755. DOI: 10.24425/afe.2023.144288.
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[16] Dhindaw, B.K., Chakraborty, M. (1974). Study and control of properties and behavior of different sand systems by application of statistical design of experiments In the 41st International Foundry Congress, (pp. 9-14). Belgique.
[17] Abdulamer, D. (2023). Utilizing of the statistical analysis for evaluation of the properties of green sand mould. Archives of Foundry Engineering. 23(3), 67-73, DOI: 10.24425/afe.2023.146664, 2023.
[18] Parappagoudar, M. Pratihar, D. & Datta, G. (2007). Linear and non-linear statistical modelling of green sand mould system. International Journal of Cast Metals Research. 20(1), 1-13. DOI: 10.1179/136404607X184952.
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Authors and Affiliations

Dheya Abdulamer
1
ORCID: ORCID
  1. University of Technology- Iraq

Utilizing of the Statistical Analysis for Evaluation of the Properties of Green Sand Mould

Dheya Abdulamer
Archives of Foundry Engineering | 2023 | vol. 23 | No 3 | 67-73 | DOI: 10.24425/afe.2023.146664
Keywords Green sand mixing time Compactability compressive strength ANOVA
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Abstract

A statistical approach was conducted to investigate effect of independent factors of the mixing time compactability and bentonite percentage on dependent variables of permeability, compression and tensile strength of sand mould properties. Using statistical method save time in estimating the dependent variables that affect the moulding properties of green sand and the optimal levels of each factor that produce the desired results.
The results yielded indicate that there are variations in the effects of these factors and their interactions on different properties of green sand. The outcomes obtained a range of permeability values, with the highest and lowest numbers being 125 and 84. The sand exhibited high values of tensile and compressive strength measuring at 0.33N/cm2 and 17.67N/cm2. Conversely it demonstrated low levels of tensile and compressive strength reaching 0.14N/cm2 and 9.32N/cm2.
These results suggest that the moulding factors and their interactions have an important role in determining properties of the green sand. ANOVA was used to assess effect of various factors on different properties of the green sand. The results obtained suggest that compactability factor play a significant effect on permeability, the mixing time or bentonite factor has a significant effect on the compressive strength and mixing time or compactability factor has a significant impact on the tensile strength with a significance level lower than 5%. It is found that neither the mixing time nor the amount of bentonite used in the green sand mix has a significant impact on its permeability. Compactability of the green sand does not has a significant effect on the compressive strength. Bentonite used in green sand mix does not have a significant impact on its tensile strength.
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Bibliography

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[4] Abdulamer, D. & Kadauw, A. (2019). Development of mathematical relationships for calculating material-dependent flowability of green molding sand. Journal of Materials Engineering and Performance. 28(7), 3994-4001. https://doi.org/10.1007/s11665-019-04089-w.
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[9] Abdulamer, D. (2021). Investigation of flowability of the green sand mould by remote control of portable flowability sensor. Archives of Materials Science and Engineering. 112(2), 70-76, DOI: https://doi.org/10.5604/01.3001.0015.6289.
[10] Abdulamer, D. & Kadauw, A. (2021). Simulation of the moulding process of bentonite-bonded green sand, Archives of Foundry Engineering. 21(1), 67-73. DOI 10.24425/afe.2021.136080.
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[16] Abdulamer, D. (2023). Impact of the different moulding parameters on properties of the green sand mould. Archives of Foundry Engineering. 23(2), 5-9. DOI: 10.24425/afe.2023.144288

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Authors and Affiliations

Dheya Abdulamer
1
ORCID: ORCID
  1. University of Technology, Iraq

Simulation of the Moulding Process of Bentonite-Bonded Green Sand

Dheya Abdulamer A. Kadauw
Archives of Foundry Engineering | 2021 | vo. 21 | No 1 | 67-73 | DOI: 10.24425/afe.2021.136080
Keywords Green sand mould Moulding process COMSOL Multiphysics Time-dependent study
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Abstract

Finite Element Method FEM via commercially available software has been used for numerical simulation of the compaction process of bentonite-bonded sand mould. The mathematical model of soil plasticity which involved Drucker-Prager model match with Mohr-Coulomb model was selected. The individual parameters which required for the simulation process were determined through direct shear test based on the variation of sand compactability. The novelty of this research work is that the individual micro-mechanical parameters were adopted depend on its directly proportional to the change of sand density during the compaction process. Boundary conditions of the applied load, roller and fixed constraint were specified. An extremely coarse mesh was used and the solution by time-dependent study was done for investigation of material-dependent behaviour of green sand during the compaction process. The research implemented also simulation of the desired points in sand mould to predict behaviour of moulding process, and prevent failure of the sand mould. Distance-dependent displacement and distance-dependent pressure have been determined to investigate the effective moulding parameters without spent further energy and cost for obtaining green sand mould. The obtained numerical results of the sand displacement show good agreement with the practical results.
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Bibliography

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Authors and Affiliations

Dheya Abdulamer
ORCID: ORCID
A. Kadauw
1 2
  1. IMKF. TU - Bergakademie Freiberg, Germany
  2. Salahddin University-Erbil, Iraq

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