METHODOLOGY 24 RESULT AND DISCUSSION 43

vi 2.2.1 Difference or Advantages of Resin Bonded sand Casting from Normal Sand Casting 10 2.2.2 Composition of Resin Bonded Sand Casting . 10 2.3 Biodegradable Resin Bonded Sand casting 11 2.3.1 Resin Polyvinyl Alcohol and Modified Urea 11 2.3.2 Hardener Catalyst . 14 2.3.3 Composition 14 2.4 Properties of Sand Mould 14 2.4.1 Permeability 15 2.4.2 Moisture Content 18 2.4.3 Compressive Strength 19 2.4.4 Tensile Strength 20 2.4.5 Transverse Strength 21 2.4.6 Loss on Ignition LOI 22 2.4.7 Biodegradability 23 Chapter Summary 23

CHAPTER 3: METHODOLOGY 24

3.1 Methodology Flow Chart . 24 3.2 Determine the appropriate method of DOE 26 3.3 Selection of Factors and Levels 26 3.4 Selection of Response Variables 26 3.5 Design matrix . 27 3.6 Preparation of Materials and Equipments . 29 3.6.1 Materials 29 3.6.2 Equipments 33 3.6.3 Sample Preparation Procedure . 34 vii 3.7 Sample Testing 36 3.7.1 Permeability Test Procedure 38 3.7.2 Moisture Content Test Procedure 40 3.8 Result Analysis 42 Chapter Summary 42

CHAPTER 4: RESULT AND DISCUSSION 43

4.1 Introduction . 43 4.2 Moisture Content 44 4.2.1 Result 45 4.2.2 Bar Chart . 46 4.2.3 Main Effects Plot Data Means for Moisture Content 47 4.2.4 Interaction Plot Data Means for Moisture Content 48 4.2.5 Discussion for Moisture Content 49 4.3 Permeability 50 4.3.1 Result 50 4.3.2 Bar Chart 51 4.3.3 Discussion for Permeability 53 Chapter Summary 54

CHAPTER 5: RESIN BONDED SAND CASTING PROCESS . 55