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Design and development of fuzzy logic-based expert system for forward and reverse mappings in resin bonded sand systems


Resin-bonded molding/core sand system is known for producing castings with good dimensional accuracy and high productivity. In the existing study, forward and inverse mappings have been considered to establish the mapping between various input variables and replies of the resin joined sand system. The concept of fuzzy logic is implemented for the said purpose. The mechanical properties namely permeability, tensile, compression, and shear strength of the core are forecasted in forward representation for various combinations of contributing process factors, such as the number of strokes, curing time, quantity of resin, and hardener. Alternatively, inverse modeling aids in obtaining the required levels of the input variables for the anticipated core properties. One thousand training data cases have been used to provide the batch mode of training to the fuzzy system. To have an adaptive fuzzy system that can perform the predictions in a better way, its knowledge base is automatically evolved through the use of genetic algorithms. Moreover, the performances of the developed forward and inverse models are verified by using experimental test scenarios.

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b1,….b8 :

Half-base widths


Compression strength




Design of experiments

f :



Fuzzy logic


Genetic algorithm


Genetic fuzzy system


Half base width


Knowledge base


No. of outputs


No. of training scenarios


Neural network

Ooi :

Predicted output




Rule base


Shear strength

Toi :

Target output


Tensile strength


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See Table 2.

Table 2 Input–Output data of the test cases

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Surekha, B., Hanumantha Rao, D., Krishna Mohan Rao, G. et al. Design and development of fuzzy logic-based expert system for forward and reverse mappings in resin bonded sand systems. Int J Syst Assur Eng Manag 13, 439–449 (2022).

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  • Resin-bonded sand system
  • Forward and reverse modeling
  • Genetic-fuzzy system