ABSTRACT
This study tend to investigate the
effect of synthetic and natural moulding sand on casting of flange like
component. In this study FUTA logo was
selected to be cast using aluminium metal. The casting was carried out and the
result was analysed according to the quality of casting. It was discovered that
for large size component using aluminium, it is better to use synthetic sand
and which is hereby recommended for casting Aluminum large size component.
TABLE OF CONTENTS
PAGES
Title
and Author’s Name i
Certification ii
Dedication
iii
Acknowledgement
iv
Abstract
v
Table
of Content vi
CHAPTER ONE
1.0
INTRODUCTION 1
1.1
Background of the study 1
1.2
Statement of the Research Problem 7
1.3
Objective of the project 8
1.4
Purpose of the project 9
1.5
Significance of the Project 10
1.6
Limitation of the study 10
CHAPTER TWO
2.0
LITERATURE REVIEW 11
2.1
History of Casting 11
2.2
Foundry Sand 12
2.2.1Constituent of a
moulding sand 14
2.2.2 Type of Foundry
Sand 17
2.2.3Properties of
moulding sand 19
2.2.4Bonding Clays 24
2.3
Determination of clay content in sand 27
2.4
Effect of the Constituent of moulding
sand 34
2.5
Practical and Realistic Defect in
permanent
mould and foundries Technological
Assessment 37
CHAPTER THREE
3.0
RESEARCH METHODOLOGY 42
3.1
Preparation of pattern 42
3.1.1Introduction 42
3.1.2Description of
the Case Study (FUTA LOGO) 43
3.1.3Materials used
for the pattern 43
3.2
Construction of moulding Box 43
3.3
Mould Making 44
3.3.1Post
Moulding operations 45
3.4 Melting/Pouring 47
3.5 Solidification of the Casting 48
3.5.1 Nucleation 48
3.5.2 There
are two kind of Nucleation 48
3.5.3 Heterogeneous
Nucleation 49
3.5.4 Grain
Structure 50
3.6 Centerline Feeding Resistance (CFR) 51
CHAPTER FOUR
4.0
RESULT AND DISCUSSION 56
4.1
Introduction 56
4.2
Surface Smoothness 57
4.3
Presence of defects 59
4.4
Lettering outlook 62
4.5
Other Details 63
4.6
Properties of each sand used 64
CHAPTER FIVE
5.0 CONCLUSION AND RECOMMENDATION 65
5.1 Conclusion 65
5.2 Recommendation 66
References 67
CHAPTER ONE
1.0 INTRODUCTION
1.1 Background
of the Study
Foundry
is a manufacturing process by which metallic products are formed by preparation
of mould, melting the required metal, pouring it into a cavity formed by the
mould and allow to solidify. In this way
the molten metal takes the shape of the cavity.
This product is cleaned and machined to desired dimension. Moulds can be made of metals or non-metals
but generally they are prepared in Sands.
(Oshungbure,
1998). Foundry Technology can also be described as the beginning and the end of
Engineering. Foundry Technology can
best be described as underdeveloped in Nigeria. Considering the fact that Technological
development of a nation is anchored on the state of her foundry
Technology. Knowing the fact that
machine component even for further production depends on the casting industry.
Thus,
it can be rightly said that, the country is still in the development
process. Foundry Technology cannot be
said to really make impact in Nigeria until the early part of the 1970’s when
product of the industry were cast iron and non-ferrous material like
aluminium. Before this period, aluminium
product was the prominent product and then very few cottage foundry workshop
were around producing aluminum pots.
Foundry
industries in Nigeria
have moved from its traditional arm chair status to a more progressive, more
customer emphatic and progress driven activity.
The
major issues that would drive foundry industry in this country are globalization
and Technology. One common thread that
runs through this issue is quality product for the customers is no doubt an
imperative for the foundry industry to meet the current and future challenges.
(Howard,
1959), Sand used to make moulds must be carefully conditioned and controlled in
order to give satisfactory and uniform results.
Ordinary Silica Zircon or Olivine are
compounded with additives to meets some requirements or alternatively
Bentonite, Silica Sand and moisture with additives will also meets some
requirements.
Refractoriness
is provided by the basic nature of the sand, cohesiveness, bind or strength
obtain by coating the sand grains with clay, such as Bentonite, Kaolite, illite
that become cohesive when moistened.
Collapsibility is obtained by adding cereals or other organic materials
that burn out when exposed to the hot metal thereby reducing the volume of
solid bulk and decreasing the strength of the restraining sand. Permeability is the ability of moulding sand
to allow gasses to escape to atmosphere during pouring of molten metal into a
well prepared mould. Good moulding sand
always represent a compromise between conflicting factors, such as grain size
of the sand particles, the amount of bonding agents such as clay, moisture
content and organic matters combined so as to obtain a satisfactory
result. Consequently some factors must
be carefully controlled to assure satisfactory results. Sand control is little concern to the
designer of casting but, it is a matter of great concern to the foundry worker
who expected to deliver casting of good and consistent quality.
In
foundry practice, moulding mixtures of varied composition are used. These multiple varieties result from the
varieties in the nature of the castings and the quality of input materials.
These
exists however some general characteristic on the basis of which moulding
mixture are classified.
In
hand moulding, usually facing and backing sand are used. Facing mixture are prepared usually from
fresh initially material and has good technological properties. The fine grain structures of sand are been
used hence the working layers of the mould which enters into direct contact
with the liquid metals made. The
thickness of this layer is 10 – 15mm depending on the thickness of the casting.
Backing
sand is meant for filling the remaining part of the mould and consists of
already used mixture, which periodically is refreshed by addition of small
amounts of silica sand (2 – 3%) and clay (1-2).
Integrated moulding mixtures are used mainly in machine moulding
mixtures are used mainly in machine moulding mixtures are used mainly in
machine moulding with aim of simplifying the process of preparation,
transportation and compaction of the mixture of the mixture, as well as ensuring
high labour productivity. They have sufficient good technological properties
and produced through refreshing of already used moulding mixtures with sand,
clay and other materials moulding mixtures for green moulds must have good
permeability and as far possible with little gas forming ability. In this
regard, it is recommended that bentonite be used as binder, their compressive
strength must be within the range (0.3 – 0.6von/m2) source?
All
materials used for the manufacture of sand mould and cores are termed moulding
materials.
In
foundry practice, the quality of the mould determines to a large extent the
quality of the cast metal product, with the exception of special moulding
materials used in the foundry for the casting non-ferrous or light alloy products. Thus the study of foundry and is very
important.
In
general, the control of sand preparation to ensure the appropriate limits of
moisture, permeability, strength and other properties is a necessary
consideration in order to guarantee good mould and minimize fetling work, with
maximum output of cast metal products.
Principal ingredients of moulding sands are:-
1.
Silica sand grains
2.
Clay or binder
3.
Additives and of course moisture
1.2 Statement of the Research Problem
i.
Determining the responsibility of conditioning
foundry sand, how it is measured and the main difficulties face in its
implementation of producing the cast object within the manufacturing sector.
ii.
Determining the impact of foundry sand
on Aluminium casting and possible defect after casting of the propose object.
iii.
Understanding the widely practice of
sand how it being carried out in the foundry shop.
Consistency
of quality is particularly important when casting most especially Aluminium and
it alloys. Nowadays, in developing
economics because of the downstream implication. In its application sand preparation is taken
as prerequisite and important as casting itself. Any deviation from the characteristics known
with a particular mixture of sand could affect the strength of the casting
(Aluminium) thereby holding both current and intending customers.
The
time dimension and varies services the foundries offers coupled with the level
of technology in use are measure of quality improvement over the last few years
in Nigeria
manufacturing of Aluminium casting and responses to foundry sand preparation in
the casting industry.
In
the developing optimum sand for Aluminium casting bring some changes in
casting, which automatically reduces wastage in casting. Considering the pouring of molten metal into
mould cavity and solidification of an aluminium alloy.
1.3 Objective of the project
The
objectives of this project are
i.
To make recommendation for the best
foundary sand mixture for Aluminium casting especially big component like
flenge.
ii.
To understand and to determine the best
sand to be used between natural moulding sand and synthetic moulding sand.
iii.
To determine the quality of sand being
used and the grain structure of sand applied.
iv.
To contribute towards inceasing the
existing body of knowledge in the implementation of the effect of foundry sand
on quality of Aluminium casting.
1.4 Purpose of the Project
The
purpose of this study includes the following:-
·
To evaluate the impact of foundry sand
preparation on the quality of aluminium casting.
·
To make recommendation for the best
foundry sand mixture for Aluminium casting especially big component like flange
·
To understand and to determine the best
sand to be used between natural moulding sand and synthetic moulding sand.
·
To determine the quality of sand being
used and the grain structure of sand applied.
1.5 Significance of the Project
·
To contribute towards increasing the
existing body of knowledge in the implementation of the effect of foundry sand
on quality of Aluminium casting.
·
To determine and to understand the best
sand to be used between natural moulding sand and synthetic moulding sand.
1.6 Limitation of the Study
The
study base on the research methodology (i.e. primary source data, Yaba College
of Technology Yaba Lagos) as strategy and vital information are not forthcoming
as expected due to problem I faced during the construction of moulding box and
the moulding for my project i.e. (FUTA LOGO).
Failure
of electricity supply during the casting of my project and a lot of
difficulties during feeling and finishing operations
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