TABLE OF CONTENT
Title page i
Certification ii
Dedication iii
Acknowledgement iv
Table of content v
Abstract viii
CHAPTER
ONE 1
1.0 Introduction 1
1.1 Statement of problem 3
1.2 Aim and objectives of the study 5
1.3 Scope of the study 5
1.4 Justification of the study 5
CHAPTER
TWO 6
2.0 Literature review 6
2.1 Background of the study 6
2.1.1 Type of tricycle 8
2.1.1.2 Recumbent delta Tricycle 10
2.1.1.3 Recumbent Tadpole 11
2.1.1.4 Recumbent hand crank 12
2.1.1.5 Recumbent Tandem 12
2.1.1.6 Special Purposes 13
2.1.17 Tricycle Rickshaw 13
2.1.1.8 Freight tricycle 14
2.2 Important of tricycle 15
2.3 Casting 15
2.4 Sand Casting 19
2.5 Moulding sand used 20
2.5.1 Refractoriness 21
2.5.2 Chemical inertness 22
2.5.3 Permeability 22
2.5.4 Surface finish 22
2.5.5 Cohesiveness 22
2.5.6 Flow ability 23
2.5.7 Collapsibility 23
2.5.8 Availability 23
2.6 Aluminium 23
CHAPTER
THREE 28
3.0 Experimental procedure 28
3.1 Pattern making 28
3.2 Casting of the product 28
3.3.1 Crucible Pot 29
3.3.2 Crucible Furnace 29
3.3.3 Drag and Cope 30
3.3.4 Rammer 30
3.3.5 Scrapper 30
3.3.6 Charcoal 30
3.3.7 Shovel 30
3.4 Steps involves in the casting operation 31
3.4.1 Sad preparation for moulding 31
3.4.2 Melting of Aluminium 32
CHAPTER
FOUR 34
4.0 Experimental procedure 34
4.1 Lather machine 34
4.2 Universal testing machine 34
4.3 Results 35
4.4 Discussion 35
CHAPTER
FIVE 37
5.0 Conclusion and Recommendations 37
5.1 Conclusions 37
5.2 Recommendation 37
Reference
ABSTRACT
A tricycle is a three wheel vehicle use in conveying
goods and human from one place to another especially is the rural and farm area
absorbing energy from moving system, drakes are generally applied to a rotating
axle or wheels but may also take other form such as a moving fluid. Brake
pedals are irregular in shape in at least the direction. Casting of the brake
pedal is to reduce the weight, the sand casting is a process by which sand is
use to prepare the mould. The pattern is made with a manna wood. Aluminiun was
used to east the part. During the casting of the product to increase the
strength of the aluminium, silicon was added to it during melting. Specimen
were also produced which was latter machined and due for tensile test.
CHAPTER
ONE
1.0 INTRODUCTION
Brakes
are generally applied to rotating wheels and may also take other forms such as
the surface of a moving fluid. Some vehicles use a combination of braking
mechanisms such as drag racing cars with both wheel brakes and a parachute or
airplanes with both wheel brakes and drag flaps raised into the air during
landing.
A
brake is a mechanical device that inhibits motion by absorbing energy from
moving system. It is used for slowing or stopping a moving vehicle wheel, axle
or to prevent its motion most often accomplished by mean of friction.
The
brake pedal is composed of two half pieces and facing and joined to one another
by two welding lines or beads which prior to their welding or subsequent to the
same have been suitably bent and to whose brake pedal body the necessary
finishing operation have been applied, such as the elimination of external
projections caused by the welding and those possible ones on making orifice for
the passing of the articulation axis of the body and other orifices such as
orifice, for other complementary passages. The joining of said half pieces and
is done by facing their two corresponding edges or by partial juxtaposition of
their respective ends, these half pieces being out of phase with each other.
Brake
pedal bodies are frequently irregular in shape in at least one direction which
has given rise to the problem that are difficult to solve, which repercussions
on both the tooling, the manufacture and the final product, all of which
negative affects the cost of the brake pedal body.
At
present much tricycle have brake pedal that is made of steel. A brake pedal may
consist of three major components namely brake pedal, rubber foot and switch
pad contact. Each brake pedal component has to undergo a series of sheet
forming processes before assembled together by welding process. Changing the
material of a brake pedal to lighter materials such as aluminum may affect the
final geometries and the manufacturing process requirement.
In
aluminum alloy brake pedal production, casting has an advantage of producing in
single process and suitable to substitute the original manufacturing process
(combination of press forming and welding process). However, castability of
brake pedal should be investigate and analyze early in design in order to form
the component without formation of effects such as cracks, segregations, pores
or misruns. There are three major approaches for castability analysis process
simulation, parametric cost estimation and feature based castability checks.
Geometric features such as under cuts, holes, sharp corners and hot spots were
recognized from a solid model of the casting and analyzed by a number of
dimensionless criteria function. These criteria were developed through a
detailed study of design heuristics used by practicing engineer and were whiten
as functions of geometric attributes of component and tool features.
An
original brake pedal design was evaluated and the geometries that were critical
modified and redesign to a new brake pedal design. The comparison between these
two designs was carried out to prove that the modified brake pedal design is
better in terms of castability.
1.1 STATEMENT OF PROBLEM
The evaluation of brake pedal has
been impressive, and has included many technologies throughout the years. In
all new developments to the braking system the number one priority is to
improve auto safety and efficiency with little cost.
Over time, the original brake pedal
have welded part and further research carried out show that casting can
eliminate the following from the original brake pedal;
1.
Welded
joints are more brittle and therefore their fatigue strength is less than the
member joined which will be eliminated when it is casted.
2.
Due
to uneven heating and cooling of the member part during the welding the members
may distrust resulting in additional stresses.
3.
Skilled
labour uses either electricity or fuel to weld which attracts additional cost.
4.
No
provision for expansion and contraction is kept in welded connection and
therefore there is possibility of racks.
5.
The
inspection of welding work is more difficult, complex and costly than the
casting work.
In
addition, the Chevrolet motor company also stressed the fact that the original
brake pedal is too heavy which make the tricycle heavy and with the casting
method, it will help to reduce the weight of the brake pedal and also the
weight of the tricycle.
The original brake pedal is too
expensive to purchase in the market to replace the original one when its goes
wear. With the help of local casting, it will make it available and cheap to
purchase in the market.
1.2 AIM AND OBJECTIVES OF THE STUDY
1.
To
reduce the weight of the brake pedal assembly.
2.
Reduction
of machining requirement compared to the original steel assembly.
3.
Elimination
of the welding and finishing operations required for the original steel welded
assembly.
4.
To
reduce the cost and the time of the production process.
5.
To
reduce the risk of serious lower limb injuries the driver in a frontal
collision.
1.3 SCOPE OF THE STUDY
The scope of study covers only
the casted brake pedal produced for experimental purpose at the polytechnic
foundry workshop.
1.4 JUSTIFICATION OF THE STUDY
·
To
examined whether the aluminium can withstand high pressure.
·
To
make alternative for the original brake pedal without cost
·
To
improve the casting process
·
To
eliminate the welding joint
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