ENGINEERING DESIGN AND CONSTRUCTION OF STIR CASTING SHOP FOR MANUFACTURING PROCESSES
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BY
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--/H2013/01430
DEPARTMENT OF ----
SCHOOL OF ---
INSTITUTE OF ---
APPROVAL PAGE
This is to certify that the research work, "engineering design and construction of stir casting shop for manufacturing processes" by ---, Reg. No. --/H2007/01430 submitted in partial fulfillment of the requirement award of a Higher National Diploma on --- has been approved.
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Supervisor Head of Department.
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External Invigilator
DEDICATION
This project is dedicated to Almighty God for his protection, kindness, strength over my life throughout the period and also to my --- for his financial support and moral care towards me.Also to my mentor --- for her academic advice she often gives to me. May Almighty God shield them from the peril of this world and bless their entire endeavour Amen.
ACKNOWLEDGEMENT
The successful completion of this project work could not have been a reality without the encouragement of my --- and other people. My immensely appreciation goes to my humble and able supervisor mr. --- for his kindness in supervising this project.
My warmest gratitude goes to my parents for their moral, spiritual and financial support throughout my study in this institution.
My appreciation goes to some of my lecturers among whom are Mr. ---, and Dr. ---. I also recognize the support of some of the staff of --- among whom are: The General Manager, Deputy General manager, the internal Auditor Mr. --- and the ---. Finally, my appreciation goes to my elder sister ---, my lovely friends mercy ---, ---, --- and many others who were quite helpful.
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Non-homogeneous particle distribution is one of the greatest problems in casting of metal matrix composites (MMC’s), because of ceramic materials have different density, melting point and boiling point. But other light materials like Aluminium, copper and magnesium etc, have less density of melting point and boiling point, so ceramic particle mixing is very difficult to light materials.
This project deals with design of the solid model components of stirrer assembly stand, stirrer rod, stirrer blade, base stand and are designed with require dimensions to design and fabricate the stir casting machine.
In this machine the stirrer blade is coupled with the stirrer shaft and motor is kept separately whereas the power is transmitted to the shaft with the help of groove pulleys. The stirrer rod designed by variation of speed (400 – 600 rpm) for mixing purpose. We can set any constant rpm or any variation rpm at any time. After mixed molten metal can be transfer into the mould with constant temperature. From this cast part improve all the mechanical properties without casting defects.
TABLE OF CONTENTS
COVER PAGE
TITLE PAGE
APPROVAL PAGE
DEDICATION
ACKNOWELDGEMENT
ABSTRACT
CHAPTER ONE
INTRODUCTION
1.1 BACKGROUND OF THE STUDY
- PROBLEM STATEMENT
- AIM AND OBJECTIVE OF THE STUDY
- SIGNIFICANCE OF THE STUDY
- SCOPE OF THE STUDY
- PROJECT MOTIVATION
CHAPTER TWO
LITERATURE REVIEW
- REVIEW OF THE STUDY
- OVERVIEW OF STIR CASTING
- MELTING OF MATRIX MATERIAL
- MECHANICAL STIRRING
- EFFECT AND OPTIMIZATION OF STIRRING PROCESS PARAMETERS
- PROCESS PARAMETERS OF STIR CASTING
- HISTORICAL BACKGROUND OF METAL CASTING
- REVIEW OF RELATED STUDIES
CHAPTER THREE
3.0 METHODOLOGY
3.1 MATERIAL SELECTION FOR STIR CASTING SETUP
3.2 COMPONENTS AND MATERIALS
CHAPTER FOUR
- MECHANISM AND FABRICATION
- FABRICATION
- RESULT AND DISCUSSION
- ASSEMBLY OF COMPONENTS
- CALCULATION
- COST ESTIMATION
- COMPARISION
- RESULT
- APPLICATION
CHAPTER FIVE
- CONCLUSION
REFERENCES
CHAPTER ONE
1.0 INTRODUCTION
1.1 BACKGROUND OF THE STUDY
In a stir casting process, the reinforcing phases are distributed into molten matrix by mechanical stirring. Stir casting of metal matrix composites was initiated in 1968, when S. Ray introduced alumina particles into aluminium melt by stirring molten aluminium alloys containing the ceramic powders. Mechanical stirring in the furnace is a key element of this process. The resultant molten alloy, with ceramic particles, can then be used for die casting, permanent mould casting, or sand casting.
Stir casting is suitable for manufacturing composites with up to 30% volume fractions of reinforcement. The cast composites are sometimes further extruded to reduce porosity, refine the microstructure, and homogenize the distribution of the reinforcement. A major concern associated with the stir casting process is the segregation of reinforcing particles which is caused by the surfacing or settling of the reinforcement particles during the melting and casting processes.
An interesting recent development in stir casting is a two-step mixing process. In this process, the matrix material is heated to above its liquids temperature so that the metal is totally melted. The melt is then cooled down to a temperature between the liquids and solidus points and kept in a semi-solid state.
For making the frame we have used nut and bolt join so that we can easily change the dimensions as per the requirement so we did drilling as per the dimension.
After completion of that we did machine work to make the components ready for assembly, mainly we used drilling process to make holes for frame, we used lathe machine to do facing, turning and boring, finally with the help of grinding machine we completed our components ready for assembling.
1.2 PROBLEM DEFINITION
Generally, stir casting process plays major role in case of Metal Matrix Composites (MMC) for attaining better mechanical properties. In this process the stir blade with rod coupled with motor is used to mix the reinforcement with the molten metals.
In small scale industries, where the capital investment is not much they cannot afford such high-priced machine. So, the aim is to find a solution to the above problem by designing and fabricating a stir casting machine that can be used with crucible furnace to melt and mix the metal matrix composites at variable speed and of low production cost. Hence the initial investment will also be hugely reduced (8000rs approx.)
1.3 AIM AND OBJECTIVE OF THE STUDY
The main aim of this work is to build a stir casting setup for manufacturing process. The objectives of the project are:
- To setup a stir casting shop using available materials
- To study the process of heating and melting aluminum metal.
- To study the application of Aluminium Matrix Composites
- To achieve uniform distribution of the reinforcement material
- To minimize porosity in the cast metal matrix composite
1.4 SCOPE OF THE PROJECT
The scope of the study is to develop a stir casting is one of the novel methods to produce metal matrix composites with more uniform distribution of matrix and reinforcement constituents. This approach involves mechanical mixing of the reinforcement particulates/particles into a molten metal bath. A crucible is heated to malt aluminum metal, with a motor and blades is placed in the crucible that helps to get uniform molten metal. The reinforcement is poured into the crucible above the melt surface and at a controlled rate, to ensure a smooth and continuous feed. As the blades rotate at moderate speeds, it generates a uniform mixing of the reinforcement particles into the melts to produce homogenous composites.
1.5 SIGNIFCANCE OF THE STUDY
Carrying out this research will help the researcher to understand how stir casting is one of the most universally used approach to manufacture particle reinforced composites and among all the fabrication techniques considered, stir casting stands out as the most economical method.
It will help the reader to learn how to setup a stir casting shop using locally available materials.
1.6 PROJECT MOTIVATION
The cost of buying the imported stir casting machine is to high, this lead to the locally setup of the device. Since locally made stir casting being economical, simple, time saving and it is having more significance than other casting process. With the help of stir casting process it is proved to manufacture castings in large quantities which is not quite possible in other casting process which are used to produce MMCs. However, advantages discussed above were points that motivate the carrying out of this research work.
CHAPTER TWO: The chapter one of this work has been displayed above. The complete chapter two of "engineering design and construction of stir casting shop for manufacturing processes" is also available. Order full work to download. Chapter two of "engineering design and construction of stir casting shop for manufacturing processes" consists of the literature review. In this chapter all the related work on "engineering design and construction of stir casting shop for manufacturing processes" was reviewed.
CHAPTER THREE: The complete chapter three of "engineering design and construction of stir casting shop for manufacturing processes" is available. Order full work to download. Chapter three of "engineering design and construction of stir casting shop for manufacturing processes"consists of the methodology. In this chapter all the method used in carrying out this work was discussed.
CHAPTER FOUR: The complete chapter four of "engineering design and construction of stir casting shop for manufacturing processes" is available. Order full work to download. Chapter four of "engineering design and construction of stir casting shop for manufacturing processes" consists of all the test conducted during the work and the result gotten after the whole work
CHAPTER FIVE: The complete chapter five of "engineering design and construction of stir casting shop for manufacturing processes" is available. Order full work to download. Chapter five of "engineering design and construction of stir casting shop for manufacturing processes" consist of conclusion, recommendation and references.
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