scholarly journals Utilising Flowability Sensor for Green Sand Mould Characterisation

2020 ◽  
Vol 1 (1) ◽  
Author(s):  
Dheya Abdulamer ◽  
Abdulkader Kadauw ◽  
Jürgen Bast
Keyword(s):  
Compaction Pressure ◽  
Casting Process ◽  
Sand Casting ◽  
Green Sand ◽  
Optimum Parameters ◽  
Good Pattern ◽  
Sensor Signals ◽  
Sand Mould ◽  
The Cost ◽  
Non Destructive

In this work, an attempt has been made to improve the sand casting process by reducing the percentage of casting defects. The enhancement of the sand casting process is based on producing green sand castings with good pattern profiles and no failures at any complex ‎points during the separation process, handling and transportation. This work ‎introduces modified, non-destructive, direct tests for measuring sand mould ‎properties using sensor readings. ‎A new flowability sensor has been used to measure the time-dependent density, ‎distance-dependent mould hardness, and distance-dependent mould strength. The ‎sensor is able to detect sand motion at the desired points during the mould-making process. The live characterisation of the green sand mould is used to determine the optimum ‎parameters for the compaction process, reduction of the moulding time, and spent ‎energy, so that the cost of the moulding and casting process will be reduced.‎ It has been found that there is a linear relationship between the properties of the green sand samples and the sensor signals. The new method facilitates the measurement of sand properties and determines the most effective moulding parameters based on the flowability sensor readings. The resultant increases in both compactibility and compaction pressure improve mould hardness and mould strength.

Investigation of flowability of the green sand mould by remote control of portable flowability sensor

2021 ◽  
Vol 112 (2) ◽  
pp. 70-76
Author(s):  
D. Abdulamer
Keyword(s):  
Remote Control ◽  
Wireless Transmission ◽  
Green Sand ◽  
Compaction Process ◽  
Moulding Process ◽  
Control Behavior ◽  
Sand Mould ◽  
System 1 ◽  
And Control ◽  
Non Destructive

Purpose: The useful data and information during the sand compaction process steps should be collected. Direct measurement methods of the sand mould properties during the actual moulding process are not adopted yet. Design/methodology/approach: In this work, a remote control system [1] have been integrated into a new flowability sensor [2]. Findings: To overcome the complexity of the tools and equipment that existed in laboratory, and in foundry. Research limitations/implications: In order to investigate, and control behavior of the moulding process of bentonite-bonded green sand process, the sensors have been equipped with the Bluetooth technology for a wireless transmission of the measured data to computers. Originality/value: This technique contributes to improve of the compaction process based on the non-destructive tests, enhances prediction of the optimum parameter conditions, and reduced the energy, and the compaction time consumed for the green sand moulding process.

Application of Taguchi-based Six Sigma method to reduce defects in green sand casting process: a case study

2019 ◽  
Vol 13 (2) ◽  
pp. 226
Author(s):  
Mahantesh M. Ganganallimath ◽  
Suraj Dhondiram Patil ◽  
E.V. Gijo ◽  
Roopa B. Math ◽  
Vijaykumar Hiremath
Keyword(s):  
Six Sigma ◽  
Casting Process ◽  
Sand Casting ◽  
Green Sand

Surface Roughness of Casted LM6 Using Natural Fibre Sand Casting Mould

2014 ◽  
Vol 903 ◽  
pp. 78-82
Author(s):  
Mohammad Hafizudin ◽  
Taufik ◽  
Mohd Razali ◽  
Nurul Farah
Keyword(s):  
Surface Roughness ◽  
Casting Process ◽  
Natural Fibre ◽  
Sand Casting ◽  
Silica Sand ◽  
Empty Fruit Bunch ◽  
The Third ◽  
Kenaf Fibre ◽  
Length Range ◽  
Sand Mould

This paper presents the investigation of sand casting process in natural fibre reactions which is utilized kenaf fibre and empty fruit brunch fibre (EFB) in order to reinforce the silica sand casting mould. The investigation was carried out on selecting sand mould which mixture with natural fibre. As a result of surface roughness of kenaf fibre mixed with silica sand, empty fruit bunch fibre mixed with silica sand and silica sand for sand mould was evaluated. The comparison of these three types of sand mould for surface roughness are analysed by using portable surface roughness tester. Technique of mixing the natural fibre and silica sand was presented. The mould was prepared using similar volume of natural fibre between kenaf fibre and empty fruit bunch fibre. The ratio of natural fibre for two type of sand fibre mould using 100 g of natural fibre and 1 kg of silica sand. The third sand mould using only 3.3 kg of silica sand without mixed with natural fibre. Total weight of three type of sand mould is 3.3 kg. Besides, this investigation was employed with 3 mm to 5 mm length range of natural fibre and mixture mutually with silica sand. The addition of natural fibre in the sand casting mould was significantly absorbing the heat of molten metal to the surrounding. As a result, the utilization of kenaf fibre and EFB fibre for sand mould were significant on improving the surface roughness of casted LM6 material.

Implementation of DMAIC methodology in green sand-casting process

2020 ◽  
Author(s):  
P.B. Ranade ◽  
Ganesh Reddy ◽  
Prasad Koppal ◽  
Ankit Paithankar ◽  
Shubham Shevale
Keyword(s):  
Casting Process ◽  
Sand Casting ◽  
Green Sand

Multi Response Optimization of Green Sand Moulding Parameters Using Taguchi-DEAR Method

2019 ◽  
Vol 895 ◽  
pp. 1-7
Author(s):  
M.J. Sandeep ◽  
Patel G.C. Manjunath ◽  
Ganesh R. Chate ◽  
Mahesh B. Parappagoudar ◽  
Umesh M. Daivagna
Keyword(s):  
Casting Process ◽  
Silica Sand ◽  
Cow Dung ◽  
Green Sand ◽  
Pareto Analysis ◽  
Design Flexibility ◽  
Complex Shapes ◽  
Response Optimization ◽  
Sand Mould ◽  
Moulding Sand

Green sand casting is treated as the most versatile casting process due to their excellent design flexibility that offer complex shapes and ability to reclaim silica sand. The modern foundries are looking for alternate moulding materials to partially replace the high cost silica sand. Cow dung is a naturally available eco-friendly binding as well as additive material and is used to partially replace the silica sand. Improper choice of the combination of moulding sand variables, such as degree of ramming, percentage of cow dung, percentage of clay, and percent of water will affect the moulding sand properties and thereby quality of casting. In the present work, Taguchi method is employed to plan and conduct experiments. Pareto analysis of variance is performed to know the contribution of variables on the moulding sand properties (i.e. compression strength, permeability, loss-on-ignition). Taguchi DEAR method is used to determine the single optimal levels of input factors that enhances the performances of all the sand mould properties. Percent of clay and cow-dung found to be the most dominating factor towards all the sand mould properties.

Sign in / Sign up

Export Citation Format

Share Document