Response surface modeling and optimization of a new impact-toughened mould material used in the shaping of sanitary ware

• A new impact-toughened mould material used in the shaping of sanitary ware is prepared.
• A second-order mathematical model between impact strength and variables is derived by response surface methodology.
• We find the optimized amount of raw materials to form the mould material.

This paper reports the synthesis of a high-impact epoxy composite toughened by the combination of amines, of which SiO2, H2O, Tween-80 and WD-60 were used as particulate filler, pore-forming agent, surface active agent and silane coupling agent, respectively. Concept of three-levels-six-factors Box-Behnken response surface design was applied for modeling and optimization of impact strength of the new impact-toughened mould material. A second-order mathematical model between the response (impact strength) and variables (SiO2, H2O, Tween-80, WD-60, epoxy resin and amines contents) was derived. Analysis of variance (ANOVA) showed a high coefficient of determination value (R2 = 91.09%). The maximum impact strength was found to be 35.7 MPa at the optimum content of raw materials of SiO2 (20.21%), H2O (31.28%), Tween-80 (2.02%), WD-60 (6.06%), epoxy resin (30.29%) and hardener (10.14%). The predicted values thus obtained were close to the experimental values indicating suitability of the model. Geometrical representation of the mathematical models in three-dimensional response surface plots and isoresponse contour plots served as a good aid in understanding the behavior of reaction under different conditions. Besides, the optimum product was characterized by thermal analysis and pore size distribution analysis. This study clearly showed that the epoxy composite could be applied in the shaping of sanitary ware.