An Approach for Establishment of Field Data Based

Model for Moulding operation

R.P. Bachute
Asst. Prof. Mechanical Dept.
G.H. Raisoni Institute of
Engineering & Technology, Pune

Dr. K. S. Zakiuddin
Dean Academics, Professor & Head,
Department of Mechanical Dept,
Priyadarshni College of Engineering, Nagpur

ABSTRACT:
Moulding operation of a cylinder head is a complex process. This process includes the worker who
makes the mould and his working environment such as the moulding machine, his posture while taking the
moulding box. In addition to this, various parameters such as tools used in moulding process, amount of energy
input by the worker, anthropometric data of the workers, working conditions such as humidity, temperature,
surrounding noise etc [1.1] also influence the productivity of moulding operation. Considering these parameters
the two important aspects to be considered are productivity of the mould of the head along with the comforts to
the workers. The aim of the work is to increase the productivity of moulding operation keeping in mind more
convenience to the workers. Out of so many parameters mentioned above we would like to find out which of
these parameters are most important for increasing the productivity and also reducing the human energy input.
Simultaneously it would be interesting to know influence of one parameter over the other.
Keywords: Sand Moulding, Cylinder Head, Human Energy Input, Mathematical Models, ANN Analysis,
Optimization, Productivity.

STATE OF ART OF ASSEMBLY PROCESS

Casting operation is one of the most important operations in manufacturing industry to produce
intricate shapes. In some industries still manual moulding process is carried out where manipulation is required.
In automobiles piston is made up of aluminium alloys. Since aluminium alloy melts at lower temperature metal
die casting method is used. This method also gives a casted part well within tolerance limit with good surface
finish. Even though some processes in casting process like moulding have been automated to varying degree,
manual moulding operation is still indispensable in processes where a high degree of manual manipulation is
required.
Literature review carried out shows that research on moulding process is carried out in motion and time
studies, Literature review reveal the researcher has not come up with empirical relation between response
variable productivity and parameters such as good workplace, better working conditions, proper design of tools,
tool arranged in proper sequence, anthropometrically work table and occupational health implications of these
parameters.

Awkward working posture can lead to discomfort or injury. Working posture is determined by

interaction of many factors in the work place such as workstation layout, visual demands, hand tool design,
anthropometric characteristics of the workers and work methods. Low or extended reaches may involve

significant trunk flexion while lateral reaches may involve axial twisting. High or far reaches may involve
significant elevation of the shoulder. Little research has been done relating occupational health risks of the
operators to the layout of the assembly as far as mathematical modelling is concerned. One factor of importance
in determining the operators posture and use of hands is the design of the work place and specially the layout of
the parts and location of work within the workplace.

PRESENT METHOD OF MOULDING

Sand casting is used to make large parts like Cylinder heads, Crank case, Cylinders etc. Molten metal is
poured into a mould cavity formed out of sand (natural or synthetic). Generally the mould is divided into two
parts, the upper one is called as Cope and Lower one is Drag.
The different steps involved in Moulding Operation of a cylinder head are as follows.

o
o
o
o
o
o
o
o

Placing the lower half of the pattern in moulding box (Drag).

Filling of the moulding sand in drag.
Ramming operation is carried out.
Extra sand from the moulding box is removed.
Venting operation is carried out so that after pouring gases can be escaped from the mould.
Turning the mould box upside down.
Removing the pattern from the mould.
Similar steps are also carried out for the Cope.

ANALYSIS OF THE PROCESS

The activity of the moulding operation of a cylinder head is a man machine system. In order to improve the
productivity & to find out the strengths/weaknesses of the method of performing the activity generally
experimental data based model is used.
Experimental database Modelling involves following steps [1.2]
Identify cause and effect.

o
o
o
o

Establish dimensional equation for phenomenon.

It is Confirmed that all physical activities are considered.
Getting dimensionless I/P quantities due to physical quantities.
Test planning includes -

Test Envelope Range of variations of an individual independent II term

Test Points Decide and specify values of independent II term

Test sequence Decide sequence in which test points to be set during

experimentation.

Planning of experimentation

Physical design of experimental setup

Execution of experiment collect i/p (Cause) & o/p (Result) data

Purification of gathered data by statistical method

Establish relationship between o/p ( Result) & i/p (Cause) using graphs.

For many man machine systems test planning part of experimentation approach is not feasible to be adopted. In
such cases one has to allow to carry out the activity as it takes place or as planned by others. The major
drawback of experimental data based modelling is we cant model a man and measure the effects of atmospheric
conditions like temperature, humidity, vibrations in the surrounding area on the efficiency of the worker. In
order to measure the effect of the parameters stated above Field Data Based Model is suitable.
The limitation of Experimental data based modelling is that for man machine systems Moulding
process it is only partially possible to plan experimentation, A.R. Bapat and J.P. Modak [1.3]. However in many
of such systems, test planning part of experimentation approach is not feasible to be adopted.

MATHEMATICAL MODEL
Any activity occurs because of four essential parameters / sub systems / issues namely System, Causes,
Effects and Extraneous Variables.
In order to develop a mathematical model for the present phenomenon following essential parameters / sub
systems / issues are identified.
System Mould
Causes knowledge of the operation, attitude towards work, experience, enthusiasm, general health status,
Pattern condition, habits, tooling's condition etc.
Extraneous variable Atmospheric temp., humidity, air circulation, surrounding noise level, disturbances etc.
In this process as regards the operator performing moulding operation causes would be :
Information of the Worker (A)
Anthropometric data of worker & Ergonomics of work table(A1), his attitude towards the work (A2), aptitude
towards the work (A3), skills of doing this work (A4), Experience of doing this work (A5), His enthusiasm
(A6), General Health status (A7), Habits (A8) etc.
Specifications of the tools used. (B)
In this case, the Material of the ram (B1), Weight of the ram (B2), Length of the vent rod (B3), Material of the
vent rod (B4), Weight of the Mould Box (B5), swab (B6) etc..
Posture adopted by an operator(C)
Specifications of the Moulding sand (D)
Responses (i.e. effects) (Y) would be :
Human Energy Input (Y1), Process time (Y2), Quality (Y3), Productivity (Y4)etc.
The influence of the above factors on the process cannot be measured. In order to optimize the process
completely it is necessary to consider the factors mentioned above and calculate the sensitive factors affecting
the process.
In order to formulate relationships we can write Y1 =

f1 [(A1,A2,A3,A4,A5,A6,A7,A8), (B1,B2,B3,B4,B5),(C),

(D1,D2,D3,D4)] ---------------------(1.1)

Y2 =

f2 [(A1,A2,A3,A4,A5,A6,A7,A8), (B1,B2,B3,B4,B5), (C),

(D1,D2,D3,D4)] ---------------------(1.2)

Y3 =

f3 [(A1,A2,A3,A4,A5,A6,A7,A8), (B1,B2,B3,B4,B5), (C),

(D1,D2,D3,D4)] ---------------------(1.3)

Y4 =

f4 [(A1,A2,A3,A4,A5,A6,A7,A8), (B1,B2,B3,B4,B5), (C),

(D1,D2,D3,D4)] ---------------------(1.4)

There are chances that some of the observed data being erroneous either from inputs or responses. The observed
data can be purified or in other words can be made more reliable for Formulation of Models.
Let us assume the quantity observed has less number of say four inputs. A, B, C, D, and the responses
Y1 and Y2. It is intended to established the mathematical relationship in a very generalized form as under :
Y1 = K1 [(A)a1, (B)b1, (C)c1, (D)d1] -----------------------------------------------(1.5)
and
Y2 = K2 [(A)a2, (B)b2, (C)c2, (D)d2] -----------------------------------------------(1.6)
Y3 = K2 [(A)a3, (B)b3, (C)c3, (D)d3] -----------------------------------------------(1.7)
Y4 = K2 [(A)a4, (B)b4, (C)c4, (D)d4] -----------------------------------------------(1.8)
This is known as exponential form of the model.
In equation (1.5) all needs to be done is to decide 5 unknowns in this equation viz., K1, a1, b1, c1, d1. Substituting
any one observation in the equation (1.5) we get,
Y1 = K1 [(A)al (B)b1 (C)c1 (D)d1]

-----------------------------------(1.5.1)

Taking log on both sides, following relation can be obtained,

Log Y1 = Log K1 + a1.Log A + b1.Log B + c1. Log C + d1.Log D ------(1.5.2)
Thus for other observation similar equations can be formed. One will get set of suppose 5 equations
which can be put in a matrix form. This amounts to getting values each of K1, a 1, b1, c1, d1. The arithmetic
average of these would probably be the reliable values of K1, a1, b1, c1, d1. Thus the exact form of model can be
deduced. To get the values of K, a, b, c & d we have to form a matrix of it and solve it using softwares like
MATLAB.
Once values of a1, b1, c1 and

d1 are

calculated, we can find out the factor which factor influences the output Y1.

Suppose index of (refer eq. 1.5.1) B is 3.2 which is the maximum of all the indices, we can conclude that factor
B influence the output Y1 most. Hence B should be kept maximum.
Similarly equations 1.6,1.7,1.8 can be solved and we can find out the sensitive factor which affects the output.
In order to reduce human energy input, Process time, to improve quality and productivity we have to control the
sensitive factor.

FUTURE WORK
This concept will be applied in a industry and the reliability of model can be studied by putting known inputs for
every observation and decide the difference in response by model and actually observed response [1.4]. This
will give us pattern of error and frequency of its occurrence. The maximum reliability of the model can be
established by ANN Simulation of the gathered data. [1.5-1.8] of the gathered data is performed.

REFERENCES
1.1 Eastman Kodak Co. Ltd, Chapter V Environment Ergonomic Design for People at Work, VAN
NUSTRAND REINHOLD, New York, 1983

1.2 H.Schenck, Jr, Theories of Engineering Experimentation Mc-Graw Hill 1961

1.3 Zakiuddin Syed Kazi, J.P. Modak (2010): Design and Development of Human Energized Chaff
Cutter, New York Science Journal, PP. 104-108.

1.4 Stamatics V. Kartalopous, Understanding Neural Networks and Fuzzy Logic. Prentice-Hall of
India. Pvt. Ltd. New Delhi. Edn 2004

1.5 J.P. Modak, Application Of AI (Artificial Intelligence) Techniques for Improvement of Quality of
Performance of a Process Unit / Man Machine System : A Philosophy. Key- Note Lecture at A
National Conference, Organised by Disha Institute of Technology and Management, Raipur, 14-16
Dec 2009.

1.6

A.R. Bapat and J.P. Modak, Various Efficiencies of a Human Powered Flywheel
Human Power a Tech. Jnl of IHPVA USA. No. 54. 2003

1.7

Motor.

Spring pp 21-23

Eastman Kodak Co. Ltd, WORK PLACE Ergonomic Design for People at work, VAN
NOSTRANS REINHOLD New York 1983

1.8

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Muwell,

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(Man

In

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