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TABLE OF CONTENT
Abstract i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables ix
List of Figures x
List Abbreviations, Symbols and Nomenclature xi
CHAPTER 1: INTRODUCTION
1
1.1 Background 1
1.2 Problem Statement 3
1.3 Objectives 4
1.4 Scope 4
Chapter Summary 4
CHAPTER 2: LITERATURE REVIEW
5
2.1 Foundry 5
2.2 Sand Casting 6
2.3 Resin bonded sand casting 8
2.3.1 Mould 9
2.3.2 Sand 10
2.3.2.1 Permeability 11
2.3.2.2Strength or Cohesiveness of Sand 12
2.3.2.3 Resistance at High Temperature 12
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2.3.2.4 Condition for Moulding Sand 14
2.3.3 Resin 15
2.3.3.1 Polyvinyl Alcohol PVA 17
2.3.3.2 Urea 19
2.3.3.3 Ammonium Lignin Sulfonate 20
2.3.3.4 Citric acid 20
2.3.3.5 Boric acid 21
2.3.3.6 Bentonite 22
2.3.3.7 Surfactant 23
2.3.4 Hardener Catalyst 23
2.4 Testing of Moulding sand 24
2.4.1 Stress of the mould 25
2.4.1.1 Compression test 25
2.4.1.2 Tensile test 26
2.4.1.3 Transverse test 27
2.4.2 Hardness test 28
2.4.3 Loss on Ignition 28
2.4.4 Moisture content test 29 Chapter Summary
29
CHAPTER 3: METHODOLOGY
30
3.1 Methodology Flow Chart 30
3.2 Determine Problem of Statement 32
3.3 Determine Objective of Study 32
3.4 Selection of Factors and Levels 32
3.5 Selection of Response Variables 33
3.6 Design Matrix 34
3.7 Biodegradable resin bonded sand sample process preparation 36 3.8 Preparation of Materials and Equipments
37 3.8.1 Materials
37
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3.8.2 Equipments 39
3.8.3 Sample Preparation Procedure 40
3.9 Sample Testing 41
3.9.1 Moisture content test 42
3.10 Results Analysis 45
Chapter Summary 45
CHAPTER 4: RESULTS AND DISCUSSION
46
4.1 Introduction 46
4.2 Results for Interpret in Minitab software 47
4.3 Moisture content test 49
4.3.1 Results 49
4.3.2 Bar chart 51
4.3.3 Main Effect Plot 52
4.3.4 Interaction Plot 53
4.3.5 Discussion of Moisture content 54
Chapter Summary 55
CHAPTER 5: RESIN BONDED SAND CASTING PROCESS
56
5.1 Introduction 56
5.2 Resin Bonded Sand Casting - Preliminary sample 57
5.2.1 Procedures 57
5.3 Resin Bonded Sand Casting - moulding and pouring 59
5.3.1 Procedures 59
5.3.2 Result 62
5.4 Discussion for resin bonded sand casting process 63
Chapter summary 63
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CHAPTER 6: CONCLUSION AND FUTURE WORK
