<p>The frozen sand mold transfer device encounters significant challenges related to mold damage and low efficiency during the manual-assisted transfer of large sand molds. This study presents a hybrid experimental design that integrates single-factor experiments with Box-Behnken response surface methodology (RSM) to optimize key parameters, including clamping force, flipping speed, and lifting speed of the transfer devices. Silicone rubber was selected as the material for the flexible contact pad in order to mitigate mold damage. A quadratic regression model (<InlineEquation ID="IEq1"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="170_2025_15361_Article_IEq1.gif" Format="GIF" Height="16" Rendition="HTML" Resolution="72" Type="Linedraw" Width="87" /> </InlineMediaObject> <EquationSource Format="TEX">${R}^{2} = 0.9986$</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <msup> <mrow> <mi>R</mi> </mrow> <mn>2</mn> </msup> <mo>=</mo> <mn>0.9986</mn> </mrow> </math></EquationSource> </InlineEquation>) demonstrated substantial interactions among the parameters investigated. The results from multi-objective optimization indicated that the optimized parameter combination led to an 18.37% reduction in clamping force while simultaneously increasing flipping and lifting speeds by 3.25% and 15.89%, respectively. These improvements enhanced both the operational efficiency and motion smoothness of the device (<InlineEquation ID="IEq2"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="170_2025_15361_Article_IEq2.gif" Format="GIF" Height="16" Rendition="HTML" Resolution="72" Type="Linedraw" Width="88" /> </InlineMediaObject> <EquationSource Format="TEX">${R}_{x}=1.0157$</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <msub> <mi>R</mi> <mi>x</mi> </msub> <mo>=</mo> <mn>1.0157</mn> </mrow> </math></EquationSource> </InlineEquation>). The findings provide a scientific basis for optimizing frozen sand mold transfer devices and possess considerable industrial application value.</p>

Hybrid experimental design methodology for non-destructive transfer of industrial-scale frozen sand molds: an improved response surface approach with engineering validation

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发表日期：

2025年3月15日

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Benfengnian Dong,
Hu Wu,
Binglin Wu,
Zhengyu An,
Yage Du,
Xuejie Liu,
Wei Zheng

摘要

The frozen sand mold transfer device encounters significant challenges related to mold damage and low efficiency during the manual-assisted transfer of large sand molds. This study presents a hybrid experimental design that integrates single-factor experiments with Box-Behnken response surface methodology (RSM) to optimize key parameters, including clamping force, flipping speed, and lifting speed of the transfer devices. Silicone rubber was selected as the material for the flexible contact pad in order to mitigate mold damage. A quadratic regression model ( ${R}^{2} = 0.9986$ $R^{2} = 0.9986$ ) demonstrated substantial interactions among the parameters investigated. The results from multi-objective optimization indicated that the optimized parameter combination led to an 18.37% reduction in clamping force while simultaneously increasing flipping and lifting speeds by 3.25% and 15.89%, respectively. These improvements enhanced both the operational efficiency and motion smoothness of the device ( ${R}_{x}=1.0157$ $R_{x} = 1.0157$ ). The findings provide a scientific basis for optimizing frozen sand mold transfer devices and possess considerable industrial application value.