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-2015
Abstract - The present study has used an ANN to predict shell molding performances – permeability number and transverse
strength- of sand moulds employed in hot metal casting. A back propagation ANN is used. This study utilized actual
experimental data in which input conditions – CaCo3% .MnO3%, Dwell time and temperature – had been varied and the
corresponding resulting performances were recorded. This data was used to both train and validate the ANN with the
eventual objective of identifying optimum input conditions that would deliver desirable moulding performance output – the
two targeted shell molding properties. The investigation used MATLAB 7.0 while the ANN’s training and validation steps
empirically varied learning rate, momentum rate, the number of hidden layers and the number of hidden neurons in each
layer. The trained neural network was observed to be capable of predicting the output within 10% error range of their
corresponding observed values.
Application Of Back Propagation Neural Network For Prediction Of Some Shell Moulding Parameters
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International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 3, Issue-12, Dec.-2015
The network begins calculating its output values by Fig 1 shows the flow chart of proposed methodology
passing the weighted inputs to the nodes in the first of this study. In this study, a BP artificial neural
layer. The resulting node outputs of that layer are network was used to model the parameters of shell
passed on, through an altogether different set of moulding. It was found that the trained network has
weights, to the second layer, and so on until the nodes very good forecasting ability. Furthermore, the trained
of the output layer compute the final outputs. In this neural network was later employed as an objective
case, each input parameter (s) and output parameter function to optimize the processes. The first step was
(t) is normalized. After training is over the network to collect the data and normalize that data between 0
simulates the value to be tested. The simulated or – 1 values by coding on Matlab7.0. In this work the
assumed outputs and actual outputs that are in total no. of samples used was sixteen and out of 16,
normalized state are then altered back to original 10 samples were used for training the network and 6
values by post processing. Denormalizing the used for testing the network. Applying BPNN
predicted values is done by the formula: algorithm in Matlab 7.0 for training and testing data
on the same network delivered the desired outputs. If
Y (i) = [x (i) – c]/e there were any large errors in outputs, then we
changed the parameters, The Architecture and The
Y (i) = nth value of normalize output Activation functions.
X (i) = Denormalize output value
c = min. value of actual value
e = difference b/w minimum and maximum values of
actual value
2.1 Artificial Neural Network (ANN) experiments. It is well known that neural network has
This study used a limited number of available been designed to optimize single quality
physically conducted actual mold making characteristics, but to consider several quality
Application Of Back Propagation Neural Network For Prediction Of Some Shell Moulding Parameters
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International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 3, Issue-12, Dec.-2015
characteristics together in the selection of process the achievable outcomes. Table-2 thus shows the
parameters; modified neural network technique was experimentally observed values listed for training and
used in Matlab 7.0.The data of shell moulding was testing.
taken from ‘Reddy and Veladri, 2007’. Their method
applied the Taguchi for parameter prediction of shell Table 2.Predicted error b/w parameters of Shell
moulding process. In this study input parameters were moulding
percentage of CaCO3, Percentage of MnO2, Dwell
time, Temperature (0c) and output (performance)
parameters were permeability and Transverse
Strength. Table1 displays the actual data.
III. RESULTS AND DISCUSSION
Table - 1 Process Parameters and Actual mold
performance as observed by Reddy and Veladri The predictions made by the back-propagation neural
(2007) network are satisfactory in most of the cases. The
network was trained with least possible error in order
to have good predictions over the percentage of
defective items produced. This particular training
requires skill, trial and error approach to determine
the activation functions and the hidden layer neurons.
The network was trained with optimal conditions to
give closer approach to the results. Figure 2-3 shows
the training of inputs and the networks stop training
after reaching the desired goal. Full set of inputs were
passed through the neural network to compute the
performance, each such pass is called an Epoch.
Application Of Back Propagation Neural Network For Prediction Of Some Shell Moulding Parameters
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International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 3, Issue-12, Dec.-2015
CONCLUSION
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Application Of Back Propagation Neural Network For Prediction Of Some Shell Moulding Parameters