2012

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

THE EFFECT OF PHENOLIC RESIN AND HARDENER

PERCENTAGE ON MECHANICAL PROPERTIES AND LOSS

ON IGNITION RESIN BONDED SAND CASTING

This report submitted in accordance with requirement of the Universiti Teknikal

Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Manufacturing Process) (Hons.)

by

NOOR ADIBAH BINTI MAT ISA

B050910122

870508-14-5550

FACULTY OF MANUFACTURING ENGINEERING

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: THE EFFECT OF PHENOLIC RESIN AND HARDENER PERCENTAGE ON MECHANICAL PROPERTIES AND LOSS ON IGNITION RESIN BONDED SAND CASTING

SESI PENGAJIAN: 2011/12 Semester 2

Saya NOOR ADIBAH BINTI MAT ISA

mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan

pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan (√)

SULIT

TERHAD

√ TIDAK TERHAD

Alamat Tetap:

BLOK H-3-7 JALAN 2/6

TAMAN SETAPAK INDAH

53100 KUALA LUMPUR

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysiasebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

Disahkan oleh:

Cop Rasmi:

Tarikh: Tarikh:

** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.

DECLARATION

I hereby, declared this report entitled “The Effect of Phenolic Resin and Hardener

Percentage on Mechanical Properties and Loss on Ignition Resin Bonded Sand

Casting” is the results of my own research except as cited in references.

Signature : ………………………………………….

Author’s Name : Noor Adibah Binti Mat Isa

Date : …………………………………………

APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM

as a partial fulfillment of the requirements for the degree of Bachelor of

Manufacturing Engineering (Manufacturing Process) (Hons.). The member of

the supervisory is as follow:

………………………………

(Dr. Nur Izan Syahriah Bt. Hussein)

i

ABSTRAK

Diterangkan di sini adalah kaedah pembuatan logam berhampiran bentuk-bersih iaitu

resin terikat proses tuangan pasir yang menggunakan fenolik sebagai resin pengikat.

Kajian ini adalah untuk menentukan faktor-faktor yang memberi kesan signifikan

kepada sifat acuan pasir iaitu resin dan pengeras seterusnya menilai lingkungan

faktor yang boleh dilaksanakan untuk menghasilkan acuan pasir fenolik. Reka bentuk

faktoran penuh dengan 9 eksperimen tiga peringkat telah dijalankan bagi menilai

kekuatan mampatan, kekuatan tegangan, kekuatan melintang dan kerugian atas

pembakaran (LOI). Reka bentuk faktorial penuh telah digunakan untuk mengkaji

kesan dua faktor keatas resin fenolik pasir acuan terikat dan interaksi yang mungkin

antara dua faktor tersebut. Data yang dikumpul kemudiannya ditukarkan kedalam

bentuk grafik iaitu carta bar, plot kesan utama dan interaksi plot. Seterusnya, plot ini

dianalisis. Daripada keputusan yang diperolehi berdasarkan empat respon, sampel

dari nisbah 9 adalah yang optimum. Ini adalah kerana nisbah ini mencapai nilai

piawaian untuk setiap respon yang dikaji. Parameter nisbah yang paling sesuai

adalah dari 9 nisbah yang mengandungi 3% daripada resin dan 20% daripada

pengeras.

ii

ABSTRACT

Describe herein a method of manufacturing a metalic to a near net-shape which is

resin bonded sand casting process that use phenolic as a resin binder. This study was

to determine the factors that significantly affect the sand mould properties which was

resin and hardener and evaluate the feasible range of factors for producing a phenolic

sand mould. The three-level full factorial design with 9 experiments run was

performed for responses that were compressive strength, tensile strength, transverse

strength and loss on ignition (LOI). DOE full factorial design was used to study the

effect of two factors on the phenolic resin bonded sand mould and their possible

interactions. The collected data was then converted into graphical form that were bar

chart, main effects plot and interaction plots and these plots were analyzed. From the

result obtained based on the four of responses, the sample from ratio 9 was the

optimum. This was because this ratio achieved the standard value for every responses

studied. The most suitable ratio parameter was from ratio 9 that contain 3% of resin

and 20% of hardener.

iii

DEDICATION

To my mother. Your love and support pass me the biggest strength.

iv

ACKNOWLEDGEMENT

First, I would like to express my gratitude to Allah S.W.T who give me the strengths

and possibility to complete this project report.

I would like to express my sincere gratitude to my supervisors, Dr. Nur Izan

Syahriah Bt Hussein for her support during this work. With constant guidance,

motivation, and constructive criticism have provided a good basis for the proposed

this study.

Thanks to all staff at SIRIM, Rasa for their valuable support, especially Mr. Shaiful

Amry Bin Mohd Jaid. I also acknowledge the great help and assistance of their

technical staff especially Mr. Syahid Samion, Mr. Saiful Fendi and Mr. Hafizi

Iberahim.

Special thanks are expressed to Mr. Azhar, technician in the material lab at FKP,

Universiti Teknikal Malaysia Melaka for helping and providing facilities to perform

part of this work.

Eventually, I would like to give my special thanks to my family and friends for their

constant encouragement, trust and love that I cherish throughout my entire time at

academia. I dedicate this project report to them. Thank you.

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) 70

5.1 Introduction 70

5.2 Loss On Ignition (LOI) 71

5.2.1 Result 71

5.2.2 Bar Chart 72

5.2.3 Main Effects Plot 73

5.2.4 Interaction Plot 74

5.2.5 Discussion for Loss on Ignition (LOI) 75

Chapter Summary 76

ix

CHAPTER 6: CONCLUSION & FUTURE WORK 77

6.1 Conclusion 77

6.2

Future work

78

REFERNCES 80

APPENDICES

A Gantt Chart PSM I

B Gantt Chart PSM II

C Compressive Strength Result

x

LIST OF TABLES

3.1

3.2

Table from design matrix that will be used to conduct the

experiments 34

The total weight of resin and hardener based on ratio that has

been obtained 35

3.3 Procedure samples preparation 41

3.4 Compressive strength test procedures 46

3.5 Tensile strength test procedures 47

3.6 Transverse strength test procedures 49

3.7

4.1

4.2

4.3

4.4

5.1

Loss on ignition (LOI) test procedure 50 Results for interpret in Minitab software 54

Result for compressive strength 55

Result for tensile strength 60

Result for transverse strength 64 Result of loss on ignition test 72

xi

LIST OF FIGURES

2.1 The steps in the production sequence in sand casting 6

2.2 The bonded sand 7

2.3 Phenolic resin bonded sand casting mould at Cheong Foundry 8

2.4 Sand that used to produce mould at Cheong Foundry 9

2.5

2.6

2.7

The universal sand strength machine 24

The attachment used on universal strength machine 25

Furnace for loss on ignition (LOI) test 27

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

3.9

3.10

3.11

3.12

3.13

3.14

3.15

3.16

3.17

3.18

3.19

General project methodology 30

The design matrix that generate by Minitab software 34

Phenolic resin bonded sand sample preparation 36

Silica sand with AFS 40-100 36

Phenolic resin 38

Resin description 38

Alphacure ester hardener 38

Hardener description 38

Sand mixer 39

Digital scale 39

Analog scale 39

Wood mould for compressive test 40

Wood mould for tensile test 40

Wood mould for transverse test 40

Motor-driven universal sand strength machine model US-M 44

Universal Testing Machine (UTM) 45

Specimen for compressive strength test 47

Specimen for tensile strength test 48

Specimen for transverse strength test 50

4.1 Bar chart for compressive strength 56

xii

4.2

4.3

4.4

4.5

4.6

4.7

4.8

4.9

5.1

5.2

5.3

Main effects plot (data means) for Compressive Strength 57

Interaction plot (data means) for Compressive Strength 58

Bar chart for tensile strength 61

Main effects plot (data means) for Tensile Strength 62

Interaction plot (data means) for Tensile Strength 63

Bar chart for transverse strength 66

Main effects plot (data means) for Transverse Strength 67

Interaction plot (data means) for Transverse Strength 68 Bar chart for LOI(%) 73

Main effects plot for LOI (%) 74

Interaction plot for LOI (%) 75

xiv

LIST OF ABBREVIATIONS, SYMBOLS AND

NOMENCLATURE

AFS - American Foundry Society

AFS GFN - Grain Fineness Number sand

DOE - Design of Experiments

F - Fahrenheit

g - gram

LOI - Loss on Ignition

kg/cm2 - Kilogram over centimeter square

Ra - Surface roughness

SIRIM - Institut Piawaian dan Penyelidikan Perindustrian Malaysia

SiO2 - Silica sand

SO2 - Sulfur dioxide

°C - Degree celsius

% - Percent

µm - micrometer

1

CHAPTER 1

INTRODUCTION

This chapter describes the general information about the study on the process of

resin bonded sand casting with a brief introduction to the background of the

research area. It also include a brief review on the items of previous research in

the area also the exact purpose of the research. The problem statement,

objectives and scope also included in this chapter.

1.1 Background

By far sand casting is the most versatile of the various method and techniques of

forming metals which include forging, punching, rolling, stamping, extrusion and

many others. Sand casting affords the designer the greatest freedom and latitude of

any forming methods with an unlimited choice of metals and alloys and can be

readily sand cast singly or by the millions (Ammen, 1979). In conventional sand

casting, the mould is formed around a pattern by ramming sand, mixed with the

proper bonding agent, onto the pattern. Molten metal is poured into the mould, and

after bit has solidified the mould is broken to remove the casting (Davis, 1993). The

quality of castings in a sand mould are influenced significantly by its properties,

such as compression strength, permeability, mould hardness and others which

depend on input parameters like sand grain size and shape, binder, water and others

(Mahesh et al., 2008).

Binders were developed to strengthen the cores, which are the most fragile

part of a mould assembly. Inorganic binders, such as clay or cement, are

2

materials that have long been used in the production of foundry moulds and

cores (James and Richard, 1986). Phenolic sand casting or phenolic ester

system is a new no bake binder technology introduces recently to the metal

casting industry (Iyer et al., 1987). The system is based on the alkaline

phenolic resin in conjunction with an organic ester that act as a co-reactant

(Iyer et al., 1987). Alkaline phenolic resin have been widely adopted since the

introduction of Alphaset in 1981 as a cold setting binder for mould and

coremaking and later BetaSet cold box process (Stevenson, 1987).

1.2 Problem Statements

Nowadays, many industries using sand casting process to produce a wide variety of

metal components with complex geometries. Quality of products is very important

for determining the efficiency of a process performed. The parameters setting play an

important role for the mould characteristic. Amount of resin and hardener included

will also influence the quality of the mould and resulting products. There are

variations range of parameters involved in resin bonded sand casting process.

The mould has to have the optimum hardness that is mould hardness number–80

(Guharaja et al., 2006) so that it takes a definite shape with accurate dimensions.

Proper mould properties will give castings a better surface finish in range 5-25µm of

surface roughness, Ra (Kalpakjian and Schmid, 2006), more accurate dimensions and

reduced penetration, drops and swells. Excessive hardness, meanwhile can cause

cracks, scabs, blows, pinholes and penetration (Granlund, 1999). In industry, it has

no recorded understanding regarding mixing all the material at different ratios. The

easiest way to do the set-up on the parameter is based on the operator or technician’s

experience, or trial and error method (SIRIM, 2012). This trial and error method is

unacceptable because it is time consuming and not cost effective. Then, using a more

systematic method, design of experiment can be used to evaluate how the parameters

of resin bonded affect the sand casting process.

3

1.3 Objective

i. To study the ratio parameter of phenolic resin and ester hardener to get the

significant condition for casting mould.

ii. To develop a design of experiment in resin bonded sand casting process.

iii. To analyze the casting mould properties of different ratio parameter

specimens in term of compressive strength, tensile strength, transverse

strength, and loss on ignition (LOI).

1.4 Scopes

This study focus on resin bonded sand casting process that uses silica sand, phenolic

resin as a binder, and ester as a hardener. Parameters selected that will affect the

quality of the mould is the percentage of resin and hardener. The range of resin that

used is 2% - 3% while the range of a hardener is 20% - 30%. In this study the design

of experiment that applied is full factorial method. After the process, a detail study

was conducted on the mould based on characteristics of compressive strength,

tensile strength, transverse strength, and loss on ignition (LOI). At the end of the

experiment, all data was collected and further discussion was made to obtain a final

conclusion. The effect of the resin binder on the cast product is not included in this

study.

1.5 Outlines of Study

For this study, six chapters are included in this report. PSM I will cover chapter 1, 2,

and 3, while for PSM II will cover chapters 4 and 5.

4

Chapter 1 includes a brief introduction to the background of the research area. It also

include a brief review on the items of previous research in the area also the exact

purpose of the research.

Chapter 2 is literature review that includes to analyse the relevant literature relevant

to the research purpose. Then, report and evaluate information that have been read in

relation to stated research question and purpose. At the end of literature review, the

research are put in clear setting, briefly reformulate the problem and the dimensions

of study.

Chapter 3 in methodology that describes the data precisely that have been selected.

It will include all the information about the relevant details.

Chapter 4 consists results and discussions for mechanical properties that is a decision

have to make according to the nature and purpose of dissertation and the nature of

the analysis. It will be evaluated according to the framework that have been used.

Chapter 5 consists results and discussions for loss on ignition properties that is a

decision have to make according to the nature and purpose of dissertation and the

nature of the analysis. It will be evaluated according to the framework that have been

used.

Chapter 6 includes the conclusion of the study that summarise the main findings that

have been discussed in detail and conclusion that have reached.

Chapter Summary

In this chapter, the information about the purpose of the study on resin bonded sand

casting have been discussed that included the problem statement, objectives and

scope. Further information will discussed in great details in next chapter.

5

CHAPTER 2

LITERATURE REVIEW

This chapter describe about the articles, books and other sources for example

dissertation, conference proceedings and so on that relevant to a particular issue

that is on significant condition on resin bonded sand casting proce ss by using

DOE method. The purpose to have this literature review is to offer an overview

of significant literature published on the related topic.

2.1 Foundry

The foundry industry use a variety of procedures for casting metal parts. These

include such processes as permanent mould casting, centrifugal casting, evaporative

pattern casting, and sand casting. In sand casting, moulds and cores are used. Cores

are required for hollow castings and must be removed after the metal has solidified

(James and Richard, 1986).

Sand casting is the most widely used casting process, utilizes expendable sand

moulds to form complex metal parts that can be made of nearly any alloy. Because

the sand mould must be destroyed in order to remove the part, called the casting,

sand casting typically has a low production rate. The sand casting process involves

the use of a furnace, metal, pattern, and sand mould. The metal is melted in the

furnace and then ladled and poured into the cavity of the sand mould, which is

formed by the pattern. The sand mould separates along a parting line and the

solidified casting can be removed (Kalpakjian and Schmid, 2006).

6

Sand casting is used to produce a wide variety of metal components with complex

geometries. These parts can vary greatly in size and weight, ranging from a couple

ounces to several tons. Some smaller sand cast parts include components as gears,

pulleys, crankshafts, connecting rods, and propellers. Larger applications include

housings for large equipment and heavy machine bases. Sand casting is also common

in producing automobile components, such as engine blocks, engine manifolds,

cylinder heads, and transmission cases (Kalpakjian and Schmid, 2006).

Figure 2.1: The steps in the production sequence in sand casting (Wang, 1995).

2.2 Resin Binder Process

Resin bonded sand casting is the same as sand casting but it is use a resin as a binder

in the process. It is also known as chemically bonded sand and no bake process. A

wide variety of chemical binders is available for making sand moulds and cores

(Brown, 2000). Binders can be used in two way which is a self-hardening mixtures.

Sand, binder and a hardening chemical are mixed together, the binder and the

hardener start to react immediately. Second is with trigged hardening which is the

sand and binder are mixed and blown or rammed into a core box (Brown, 2000).

Binders were developed to strengthen the cores, which are the most fragile part of a

7

mould assembly. Curing of the binder system begins immediately after all

components are combined (James and Richard, 1986).

Figure 2.2: Sand is again packed tightly around a wood or metal pattern, but the sand is bonded with a self-setting organic binder. The bonded sand has higher strength and improved dimensional control, compared to green sand (American Foundry Society, 2005).

2.2.1 Binder System Development

In the 1940s, sand cores were made with oven-baked, oil-bonded sand. The moulding

processes during this era consisted of green sand for smaller castings and skin-dried

green sand or “dry sand” (oven-baked pitch and clay-bonded moulds) for larger

castings. The oil sand process was used to construct “core moulds” by fastening

sections of cores together in ways that would form moulds. These core moulds

produced castings with better dimensional properties than those made in clay-bonded

sands.

Following World War II, drastic changes occurred in the core and mould making

processes used for casting aluminium. Heat-cured “shell resin” sand systems which

produced hollow, shell-like cores and carbon dioxide gas-hardened silicate systems

which made the more conventional solid cores were introduced during the 1950s. In

the decades that followed, heat-cured hotbox binders, no-bake systems which