v
TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables x
List of Figures xi
List Abbreviations, Symbols and Nomenclature xiv
CHAPTER 1: INTRODUCTION
1
1.1 Background
1 1.2
Problem Statement 2
1.3 Objectives
3 1.4
Scopes 3
1.5 Outline of Project
3 Chapter Summary
4
CHAPTER 2: LITERATURE REVIEW
5
2.1 Foundry
5 2.2
Resin Binder Process 6
2.2.1 Binder System Development 7
2.3 Mould
8 2.4
Sand 9
vi 2.4.1 Type of Foundry Sand
10 2.4.2 Conditions for Moulding Sand
11 2.5
Resin 12
2.5.1 AlphaSet Resin 13
2.5.2 Advantages and Disadvantages 14
2.6 Hardener
15 2.6.1 Hardening Mechanism
16 2.6.2 Triggered Hardening System
16 2.7
Bonding Power 16
2.8 Design and Analysis of Experiment
17 2.9.1 Types of DOE
19 2.8.1.1 Taguchi Method
19 2.8.1.2 Classical Factorial design
19 2.8.1.3 Response Surface Methodology
20 2.8.1.4 Full Factorial Design
22 2.8.1.4.1 Three-level Factorial Design
22 2.8.2 Research that use Full Factorial
23 2.9
Testing of Moulding sand 23
2.9.1 Compressive Strength 24
2.9.2 Tensile Strength 25
2.9.3 Transverse Strength 26
2.9.4 Loss on Ignition LOI 26
Chapter Summary 28
CHAPTER 3: METHODOLOGY
29
3.1 Methodology Flow Chart
29
3.2 Determine Problem of Statement
31 3.3
Determine Objective of Study 31
3.4 Selection of Factors and Levels
31 3.5
Selection of Response Variables 32
3.6 Design Matrix
33 3.7
Phenolic Resin Bonded Sand Sample Process 36
3.8 Preparation of Materials and Equipments
37 3.8.1 Materials
37 3.8.2 Equipments
39 3.8.3 Sample Preparation Procedure
41 3.9
Sample Testing 44
3.9.1 Compressive Strength Test Procedures 46
3.9.2 Tensile Strength Test Procedures 47
3.9.3 Transverse Strength Test Procedures 49
3.9.4 Loss on Ignition LOI test Procedures 50
3.10 Results Analysis 51
Chapter Summary 51
CHAPTER 4:RESULT AND DISCUSSION OF MECHANICAL PROPERTIES
53
4.1 Introduction
53 4.2
Results Interpret from Minitab Software 54
4.3 Compressive Strength
55 4.3.1 Result
55 4.3.2 Bar Chart
56 4.3.3 Main Effects Plot
57 4.3.4 Interaction Plot
58 vii
viii 4.3.5 Discussion for Compressive Strength
59 4.4
Tensile Strength 59
4.4.1 Result 60
4.4.2 Bar Chart 61
4.4.3 Main Effects Plot 62
4.4.4 Interaction Plot 63
4.4.5 Discussion for Tensile Strength 64
4.5 Transverse Strength
64 4.5.1 Result
64 4.5.2 Bar Chart
65 4.5.3 Main Effects Plot
66 4.5.4 Interaction Plot
67 4.5.5 Discussion for Transverse Strength
68 Chapter Summary
69
CHAPTER 5:RESULT AND DISCUSSION OF LOSS ON IGNITION LOI
