This document summarizes a study comparing the green sand mould casting process to the shell mould casting process. Some key findings of switching from green sand to shell mould include:
- Yield increased from 65% to 78% due to less wastage in the shell mould process.
- Productivity more than doubled from 30kg to 72kg per person per day.
- Rejection rates decreased substantially from 8% to 3.5% due to fewer defects from the shell mould process.
- Sand usage was reduced by 9% from a sand to metal ratio of 1:14 to 1:5.
The present research work demonstrates the
preparation of Copper Oxide Nanoparticles (CuO NPs) and
investigates the thermo mechanical properties of the CuO NPs
embedded in the polymer composites experimentally. In this study,
CuO NPs were produced by aqueous precipitation method and
morphology of the NPs was studied using Field Emission
Transmission Electron Microscope (FESEM). Epoxy resin and glass microsphere were considered the base material for the preparation of
the Nano based polymer composites. In order to fabricate the Nano
based polymer composites, CuO NPs with 1.0wtpercentage were
embedded in the base material by means of compression moulding
press. Nano composites proved higher thermal conductivity
enhancement rather than the base material. While comparing to the
base material, the maximum four-point bending strength of 415 MPa
was obtained from the Nano based polymer composites. The test
results obtained from the TG study revealed that an addition of CuO
NPs had acted as the thermal retardant and CuO NPs had delayed
thermal degradation of the Nano based polymer composites. Based
on the test results, it can be suggested that the newly fabricated
nanocomposites have achieved the improved thermal and mechanical
properties.
Friction Stir Welding, a type of welding which was
discovered in the year of 1991 with a few countable methods
and processes. But today it is one of the necessary and
important type of welding techniques. To develop it, several
researchers showed their interests in this technique. Today,
it acts as the heart of welding of automobiles. Thousands of
inventions has been made in field of Friction Stir Welding
and also successfully being implemented. If a researcher
tries to make some research in this field, he has to go
through thousands of journals where hours of time is being
consumed. To solve that problem several Re-view journals
are being published and also successfully solved this issue
of time consumption. In this paper, similarly a re-view of
several important and different types of papers are discussed
with their results, outcomes, the parameters being performed
for analysis.
This paper also discusses about various methods and various
metals as tools and job materials. It will be much easier and
lenient to understand from this paper to research. The
authors of the papers also clearly explained about the usages
and applications of their methods and provided several
statistical data for clear observation of their methods
Numerical simulation of friction stir butt welding processes for az91 magnesi...eSAT Journals
Abstract Friction Stir Welding (FSW) is a solid state welding process. In particular, it can be used to join high-strength aerospace magnesium and other metallic alloys that are hard to weld by conventional fusion welding. It was performed on 4 mm thickness AZ91 Magnesium alloy. Magnesium alloy have more advantage than aluminum such as light weight, softer, tendency to bend easily, cost effective in terms of energy requirements so magnesium alloy has selected in this FSW technique. In friction stir welding (FSW), a momentous residual stress is present in weld due to complex nature of fixturing system compared to fusion welding. These residual stresses can affect properties of welded components during service. Therefore, for estimating magnitude of welding residual stresses and their nature of distribution along with thermal history, a three dimensional non- linear thermo-mechanical finite element (NLTMFE) model using ABAQUS/ CAE package was developed for butt welded magnesium alloy AZ91. The objective of this work is to predict the temperature distribution in both materials and evaluate the mechanical properties during the friction stir welding on magnesium alloy. Keywords: Fsw, Nltmfe, Abaqus, Cae, Az91.
Numerical simulation of friction stir butt welding processes for az91 magnesi...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
The main objective of this paper is to
determine casting defects generally happening in an
aluminium die casting process and efforts have been
taken to identify the tools which eliminate the casting
defects. In global prospective this study briefs the
application of the various tools that are used in the
industries for improvement of quality in foundry
industry. In our national prospective these tools are not
so popular, hence this study will help us to utilise the
available technology through which the productivity is
enhanced with safe and economical means. The QC
tools were used to analyse the casting condition of the
given pattern with three dimensional simulations for the
result preparation. This work has been carried out to
improve the quality of the pattern which is made with
gravity die casting process and this was achieved
through continuous quality control operation with QC
tools, then it was taken to test in some simulation
software. The latest trend available in casting and
foundry shops are the scientific approach in
optimization of all kind of fields including optimization
of defects in castings. These trends are incorporated in
the analysis of aluminium die casting.
The present research work demonstrates the
preparation of Copper Oxide Nanoparticles (CuO NPs) and
investigates the thermo mechanical properties of the CuO NPs
embedded in the polymer composites experimentally. In this study,
CuO NPs were produced by aqueous precipitation method and
morphology of the NPs was studied using Field Emission
Transmission Electron Microscope (FESEM). Epoxy resin and glass microsphere were considered the base material for the preparation of
the Nano based polymer composites. In order to fabricate the Nano
based polymer composites, CuO NPs with 1.0wtpercentage were
embedded in the base material by means of compression moulding
press. Nano composites proved higher thermal conductivity
enhancement rather than the base material. While comparing to the
base material, the maximum four-point bending strength of 415 MPa
was obtained from the Nano based polymer composites. The test
results obtained from the TG study revealed that an addition of CuO
NPs had acted as the thermal retardant and CuO NPs had delayed
thermal degradation of the Nano based polymer composites. Based
on the test results, it can be suggested that the newly fabricated
nanocomposites have achieved the improved thermal and mechanical
properties.
Friction Stir Welding, a type of welding which was
discovered in the year of 1991 with a few countable methods
and processes. But today it is one of the necessary and
important type of welding techniques. To develop it, several
researchers showed their interests in this technique. Today,
it acts as the heart of welding of automobiles. Thousands of
inventions has been made in field of Friction Stir Welding
and also successfully being implemented. If a researcher
tries to make some research in this field, he has to go
through thousands of journals where hours of time is being
consumed. To solve that problem several Re-view journals
are being published and also successfully solved this issue
of time consumption. In this paper, similarly a re-view of
several important and different types of papers are discussed
with their results, outcomes, the parameters being performed
for analysis.
This paper also discusses about various methods and various
metals as tools and job materials. It will be much easier and
lenient to understand from this paper to research. The
authors of the papers also clearly explained about the usages
and applications of their methods and provided several
statistical data for clear observation of their methods
Numerical simulation of friction stir butt welding processes for az91 magnesi...eSAT Journals
Abstract Friction Stir Welding (FSW) is a solid state welding process. In particular, it can be used to join high-strength aerospace magnesium and other metallic alloys that are hard to weld by conventional fusion welding. It was performed on 4 mm thickness AZ91 Magnesium alloy. Magnesium alloy have more advantage than aluminum such as light weight, softer, tendency to bend easily, cost effective in terms of energy requirements so magnesium alloy has selected in this FSW technique. In friction stir welding (FSW), a momentous residual stress is present in weld due to complex nature of fixturing system compared to fusion welding. These residual stresses can affect properties of welded components during service. Therefore, for estimating magnitude of welding residual stresses and their nature of distribution along with thermal history, a three dimensional non- linear thermo-mechanical finite element (NLTMFE) model using ABAQUS/ CAE package was developed for butt welded magnesium alloy AZ91. The objective of this work is to predict the temperature distribution in both materials and evaluate the mechanical properties during the friction stir welding on magnesium alloy. Keywords: Fsw, Nltmfe, Abaqus, Cae, Az91.
Numerical simulation of friction stir butt welding processes for az91 magnesi...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
The main objective of this paper is to
determine casting defects generally happening in an
aluminium die casting process and efforts have been
taken to identify the tools which eliminate the casting
defects. In global prospective this study briefs the
application of the various tools that are used in the
industries for improvement of quality in foundry
industry. In our national prospective these tools are not
so popular, hence this study will help us to utilise the
available technology through which the productivity is
enhanced with safe and economical means. The QC
tools were used to analyse the casting condition of the
given pattern with three dimensional simulations for the
result preparation. This work has been carried out to
improve the quality of the pattern which is made with
gravity die casting process and this was achieved
through continuous quality control operation with QC
tools, then it was taken to test in some simulation
software. The latest trend available in casting and
foundry shops are the scientific approach in
optimization of all kind of fields including optimization
of defects in castings. These trends are incorporated in
the analysis of aluminium die casting.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Finite element simulation of hybrid welding process for welding 304 austeniti...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Mechanical properties and reliability of glass aluminium composite as insert ...eSAT Journals
Abstract Plastic injection mold made of tool steel is generally utilized for large lots production. Running for small lots of product is a new trend of demand, so that the mold would be relatively expensive and not competitive. The aim of the present work is to find an alternative material and process for low cost injection mold that suitable for small lots. For these reasons, aluminum-glass-acrylic particulate composite would be proposed as a material for manufacturing of low cost plastic injection mold. In this work, an insert mold as part of the injection molding was selected for the case study. Composite was examined to know its characteristics. The part with size of (80mm x 10mm x 10mm) and (30mm x30mm x30mm) made of particulate composite material was selected as specimen. Material of the specimen was aluminum powders (<297><74><74 μm); the volume ratio is 1:1:1. Acrylic was used for binder when composite made by layer manufacturing method, using Selective Heater Melting (SHM) machine. The specimen was prepared into three steps: manufacturing of composite (green specimen) by SHM machine, heating green specimen to burn up the acrylic, and resin impregnation. There were 3 types of specimens: green specimen before heating at 700°C, green specimen after heating at 700°C, and green specimen after heating at 700°C that continued by resin impregnation. Tests was performed to investigate its bending strength, surface hardness, surface roughness, and dimensional error. The other composite (specimen) was insert mold, made by layer manufacturing method, using SHM machine. Case study was carried out by testing an insert mold to know the reliability of insert mold. Bending strengths of green specimen, before and after heating at 700°C, were 2.07 and 8.23 MPa, respectively; and after resin impregnation was 17.15 MPa. Dimensional errors in the direction of X, Y, and Z-axis for green specimen of (30mm x 30mm x30mm) before heating at 700°C were 8.65, 2.7, and 3.8 mm, respectively; and after heating at 700°C were 7.90, 1.10 and 0.90 mm, respectively. Surface roughness of green specimen before and after heating at 700°C were 46.12 and 33.48 μm, respectively; and after resin impregnation was 12.17 μm. Surface hardness of specimen after resin impregnation was 14.199 BHN. The amount of plastic parts that could be produced by insert mold was 120 and 126 pieces. Although mechanical strength of this composite was lower than that of tool steel that used for common plastic injection mold, but this composite material was less expensive and suitable for small lots production. Keywords: Layer manufacturing, Selective Heater Melting (SHM) machine, green specimen, insert mold.
Experimental Study on Surface Roughness by Using Abrasive ParticlesIJERA Editor
New advancement of technology and never satisfying demands of the civilization are putting huge pressure on the natural fuel resources and these resources are at a constant threat to its sustainability. Surface finish has a vital influence on functional properties such as wear resistance and power loss due to friction on most of the engineering components. Voltage, mesh number, revolutions per minute (rpm) of electromagnet, and percentage weight of abrasives has been identified as important process parameters affecting surface roughness. The experiments were planned using response surface methodology and percentage change in surface roughness (ΔRa) was considered as response. Analysis of experimental data showed that percentage change in surface roughness (ΔRa) was highly influenced by mesh number followed by percentage weight of abrasives, rpm of electromagnet, and voltage. The process has been investigated extensively in the finishing of cylindrical surfaces. The surface finish was found to improve significantly with an increase in the grain size, relative size of abrasive particles vis-à-vis the iron particles, feed rate and current. Super finishing is a micro-finishing process that produces a controlled and smooth surface condition on work pieces. It is not primarily a sizing operation, its major purpose is to produce a surface on a work piece capable of sustaining uneven distribution of a load by improving the geometrical accuracy. The wear life of the parts micro finished to maximum smoothness is extended considerably. According to the design of experimentation, mathematical model for Lapping operation on advance ceramic material is proposed. In order to get minimum values of the surface roughness, optimization of the mathematical model is done and optimal operation of the examined factors is going to be determined. The obtained res
Comparative analysis on mould filling of a413 aluminium alloy in sand and eva...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
A war on thrift? A perversion of the natural order? A mad experiment? As more central banks push their deposit rate structures into negative territory, a vigorous debate has erupted among economists, investors and policy officials about the appropriateness, effectiveness and consequences of negative interest rates.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Finite element simulation of hybrid welding process for welding 304 austeniti...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Mechanical properties and reliability of glass aluminium composite as insert ...eSAT Journals
Abstract Plastic injection mold made of tool steel is generally utilized for large lots production. Running for small lots of product is a new trend of demand, so that the mold would be relatively expensive and not competitive. The aim of the present work is to find an alternative material and process for low cost injection mold that suitable for small lots. For these reasons, aluminum-glass-acrylic particulate composite would be proposed as a material for manufacturing of low cost plastic injection mold. In this work, an insert mold as part of the injection molding was selected for the case study. Composite was examined to know its characteristics. The part with size of (80mm x 10mm x 10mm) and (30mm x30mm x30mm) made of particulate composite material was selected as specimen. Material of the specimen was aluminum powders (<297><74><74 μm); the volume ratio is 1:1:1. Acrylic was used for binder when composite made by layer manufacturing method, using Selective Heater Melting (SHM) machine. The specimen was prepared into three steps: manufacturing of composite (green specimen) by SHM machine, heating green specimen to burn up the acrylic, and resin impregnation. There were 3 types of specimens: green specimen before heating at 700°C, green specimen after heating at 700°C, and green specimen after heating at 700°C that continued by resin impregnation. Tests was performed to investigate its bending strength, surface hardness, surface roughness, and dimensional error. The other composite (specimen) was insert mold, made by layer manufacturing method, using SHM machine. Case study was carried out by testing an insert mold to know the reliability of insert mold. Bending strengths of green specimen, before and after heating at 700°C, were 2.07 and 8.23 MPa, respectively; and after resin impregnation was 17.15 MPa. Dimensional errors in the direction of X, Y, and Z-axis for green specimen of (30mm x 30mm x30mm) before heating at 700°C were 8.65, 2.7, and 3.8 mm, respectively; and after heating at 700°C were 7.90, 1.10 and 0.90 mm, respectively. Surface roughness of green specimen before and after heating at 700°C were 46.12 and 33.48 μm, respectively; and after resin impregnation was 12.17 μm. Surface hardness of specimen after resin impregnation was 14.199 BHN. The amount of plastic parts that could be produced by insert mold was 120 and 126 pieces. Although mechanical strength of this composite was lower than that of tool steel that used for common plastic injection mold, but this composite material was less expensive and suitable for small lots production. Keywords: Layer manufacturing, Selective Heater Melting (SHM) machine, green specimen, insert mold.
Experimental Study on Surface Roughness by Using Abrasive ParticlesIJERA Editor
New advancement of technology and never satisfying demands of the civilization are putting huge pressure on the natural fuel resources and these resources are at a constant threat to its sustainability. Surface finish has a vital influence on functional properties such as wear resistance and power loss due to friction on most of the engineering components. Voltage, mesh number, revolutions per minute (rpm) of electromagnet, and percentage weight of abrasives has been identified as important process parameters affecting surface roughness. The experiments were planned using response surface methodology and percentage change in surface roughness (ΔRa) was considered as response. Analysis of experimental data showed that percentage change in surface roughness (ΔRa) was highly influenced by mesh number followed by percentage weight of abrasives, rpm of electromagnet, and voltage. The process has been investigated extensively in the finishing of cylindrical surfaces. The surface finish was found to improve significantly with an increase in the grain size, relative size of abrasive particles vis-à-vis the iron particles, feed rate and current. Super finishing is a micro-finishing process that produces a controlled and smooth surface condition on work pieces. It is not primarily a sizing operation, its major purpose is to produce a surface on a work piece capable of sustaining uneven distribution of a load by improving the geometrical accuracy. The wear life of the parts micro finished to maximum smoothness is extended considerably. According to the design of experimentation, mathematical model for Lapping operation on advance ceramic material is proposed. In order to get minimum values of the surface roughness, optimization of the mathematical model is done and optimal operation of the examined factors is going to be determined. The obtained res
Comparative analysis on mould filling of a413 aluminium alloy in sand and eva...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
A war on thrift? A perversion of the natural order? A mad experiment? As more central banks push their deposit rate structures into negative territory, a vigorous debate has erupted among economists, investors and policy officials about the appropriateness, effectiveness and consequences of negative interest rates.
Optimization of ceramic shell mold materials in investment castingeSAT Journals
Abstract Ceramic shell investment casting process is used to produce high quality casting products with relatively close dimensional tolerance. The refractory material use as primary coat on shell mold of investment casting play a very important role to form surface finish. Zircon flour though costly, is being used as a primary slurry material in the ceramic shell investment casting process. To reduce the cost of primary slurry material, some alternate refractory material like, alumina, silica, used with zircon to enhance properties. The hardness test of the casted samples and micro-examination under binocular metallurgical microscope has been done to study the micro-characteristic evaluation. The result reveals that the ceramic shell contains 100% zircon primary refractory gives the best results. Keywords: shell mold, refractory, slurry, investment casting
Aluminium Matrix Composites (AMC’s) are widely used in aerospace, automotive,
structural and marine applications due to their high strength to weight ratio, corrosion
resistance. In AMC one of constituent is aluminium or its alloy which forms a network
called as matrix phase and other constituent is embedded in matrix made of harder material
generally ceramic or non metallic material called as reinforcement. Various processing
techniques are available for manufacturing of AMC’s. Stir casting is one of the economical
and extensively used methods to enhance attractive properties of AMC’s. This paper
presents an overview of stir casing process, process parameter and preparation of AMC
using aluminium alloy as matrix phase and alumina (Al2O3) as reinforcement by varying
their proportion.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
AN APPROACH FOR ENERGY CONSERVATION ON PARTIALLY LATERISED KHONDALITE ROCKS U...IAEME Publication
Partially Lateritised Khondalite (PLK) rocks are the bauxite mining waste materials generated during mining and dumped at the mining site, create environmental pollution. These waste
rocks can be utilized as filler materials for different industrial applications after grinding to suitable mesh size. Thermal shock treatment on ore is used for grain boundary breakage and size reduction,due to thermal shock treatment the surface adsorbed gangue minerals also releases and expose new
surface area in the ore. Comminution study is used after this treatment for further reduction in size.
Partially Lateritised Khondalite (PLK) rocks are the bauxite mining waste materials
generated during mining and dumped at the mining site, create environmental pollution. These waste
rocks can be utilized as filler materials for different industrial applications after grinding to suitable
mesh size. Thermal shock treatment on ore is used for grain boundary breakage and size reduction,
due to thermal shock treatment the surface adsorbed gangue minerals also releases and expose new
surface area in the ore. Comminution study is used after this treatment for further reduction in size.
In comminution study, ball mill has good selective grinding performance. This paper deals with the
effect of thermal shock treatment on grinding characteristics of PLK rock and the overall energy
savings achieved. Alumina based filler/ceramic materials were used in different industries. Thermal
shock of the samples was evaluated using water quench test. Surface deterioration level of samples
was monitored by image analysis before and after quenching. A total energy saving of the order of
52.8 % could be achieved when a sample preheated at 1123 K for 60 minutes followed by coldwater
quenching and grinding.
AN EXPERIMENTAL STUDY ON PROPERTIES OF TERNARY BLENDED CONCRETE USING GGBS AN...AM Publications
Ground granulated blast furnace slag (GGBS) is a by-product obtained from the blast furnaces used in the iron manufacturing industry. The disposal of the marble powder obtained from marble industry constitutes one of the environmental problems around the world. One of the possible solutions for the effective use of GGBS and marble powder is to partially replace cement in concrete. This paper presents the results of an experimental study on concrete in which the cement is partially replaced by both GGBS and marble powder. In this study, different percentages of GGBS and marble powder are used for partial replacement of cement by 30%. Tests conducted includes workability of fresh concrete (Slump test), strength of hardened concrete (Compressive strength, Split tensile strength and Flexural strength) and durability properties of concrete (Chloride resistance and Sulphate resistance).
The Effect of Milling Times and Annealing on Synthesis of Strontium Titanate ...AM Publications
Analysis of microstructure of Strontium titanate (SrTiO3) phase obtained by milling and annealing of
SrCO3 and TiO2 precursors. However, the material properties for strontium titanate require a careful control of
crystallite structure as well as microstructure design to meet a specific application. The mixture of strontium
carbonate (SrCO3) and tintanium oxide (TiO2) powders was used to obtain SrTiO3 phase by using vibrator ball mill
with ball to powder ratio 10:1 and heat treatment processes. The size of powder particles was determined by a laser
particle analyzer (PSA). The X-ray diffraction methods were used for qualitative, quantitative phase analyses and for
crystallite size and lattice distortion determination. The milling process of strontium carbonate and tintanium oxide
mixture causes decrease of the mean particle size and crystallite size of involved phases. The X-ray diffraction
investigations of SrCO3 and TiO2 mixture milled for 60 hours and annealed at 900°C with 24 h of holding time
enabled the identification of SrTiO3 phase. Annealing the sample of the particles at 900 0C has resulted in a dense
compact and promoted the formation of particles containing nanocrystallites. The crystallite-growth samples of
SrTiO3 phase were dependent on temperature and time of their annealing
Effects of cryogenic treatment on tool steel aisi d6eSAT Journals
Abstract
In present technological modern age. All the manufacturers adopt that process which governs to higher productivity that has been achieved by the various treatment of tool steel. These conventional processes improve no of characteristics to fulfill desired purpose. But all these process does not provided fully satisfaction from conventional heat treatment process. Thus a new process is being additionally employed for improving mechanical properties called cryogenic treatment process or sub-zero treatment of tool steels. During this process tool steel is proceed below Atmospheric tem. That is in minus about (-1960 C or 3100 F). Due to cooling, steel alter their mechanical properties like wear resistance, Hardness, toughness, fatigue life micro-structure alteration etc. Cryo-treatment not only improve its mechanical properties but also improve thermal properties, electrical properties & easier machining etc. in this paper cryogenic treatment of tool steel AISI-D6 is perform and study is made for wear-resistance, Hardness, toughness, with respect to untreated test specimen of same, we have got improved wear-resistance capacity improve hardness as well as toughness.
Keywords – AISI-D6 tool steel, cryogenic process, wear resistance, Hardness, Toughness.
Preliminary study of on cladding process on gray cast iron substrateeSAT Journals
Abstract Cladding, also called as hardfacing or surfacing, is a deposition process with a purpose of improving the properties of the substrate accomplished either using laser beam or arc as the heat source for the process. Filler material used in the process is deposited layer-by-layer until covering required thickness before being machined to achieve the final dimension. Gas metal arc welding is seen as the best method for accomplishing the cladding operation as the alternative for laser cladding in term of operation cost. The process parameters of gas metal arc welding are discussed on in the aspect of the cladding process. Grey cast iron with its inherent brittleness characteristic is difficult to be weld cladded because the thermal cycle of the cladding process can cause the material to crack. It is understood that the coarse graphite flake structure that gives the lack of ductility characteristic to the material and cause the material to crack when suffer the stress occur during the temperature drop of the process. Nickel based filler material is seen as the best choice to be used for the deposition process because of its ability to precipitate carbon in its free form of graphite and prevent the migration of carbon from cast iron substrate thus avoiding the formation of hard carbide phase. The addition of tungsten carbide in the matrix of nickel base alloy gives the filler material good hardness and wear resistant properties. This paper serves as the preliminary study to get an insight into the understanding of cladding process on cast iron as the substrate before performing the experiment of the cladding operation. Keywords: Cladding, Hardfacing, Cast Iron, Nickel Based Alloy
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Studies on aluminium silicon eutectic alloy casting and design approach of it...
Shruthi paper
1. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
__________________________________________________________________________________________________
Volume: 03 Issue: 05 | May-2014, Available @ http://www.ijret.org 594
PRODUCTIVITY IMPROVEMENT OF CASTINGS, SWITCHING TO
SHELL MOULD PROCESS FROM GREEN SAND MOULD PROCESS
Shruthi Y C1
, Ramachandra C G2
, Veerashekhar M3
1
MTech Scholar, ME Department, Srinivas Institute of Technology, Valachil, Mangalore
2
Associate professor, ME Department, Srinivas Institute of Technology, Valachil, Mangalore
3
Director, Adishakthi Castings, Shimoga
Abstract
The creation and application of technology to monitor and control the production and delivery of products and service in casting
foundries has gained importance and are necessary to sustain in competitive market conditions. Setup of the industries as applied to
casting foundries need timely setup and changes to cope up with the increasing demand from the customers as foundries have great
demand for the products produced, in numerous fields. In this paper various parameters of importance are improved by employing
shell mould process to the castings which were previously produced by green sand mould process.
Keywords: shell mould process, Green sand mould process, foundries.
----------------------------------------------------------------------***--------------------------------------------------------------------
1. INTRODUCTION
An object made by pouring molten metal into the mould,
usually liquid metal is poured into the mould which contains a
hallow cavity of desired shape, it is then allowed to solidify.
The solidified part is known as casting which is removed from
the mould by proper removal procedures to complete the
process. Casting is one of the oldest manufacturing processes
from which simple and complicated shapes can be made from
any metal that can be melted. Around 6.5million kg of casting
are produced every year. The most common materials used for
casting are grey iron, ductile iron, aluminum alloys and copper
alloys.
The cast component has a shape, size, chemical composition
and metallurgical microstructure which is determined by
engineering decisions arrived by design engineers, pettren
makers, casting engineers and manufacturing engineers along
with technically well versed team who work together as a
team to manufacture castings in intended time and in a cost
effective manner. Castings produced may be small part of
useful device or it may be the entire device. Foundry is a
casting factory which equipped for making moulds, melting
and handling molten metal, performing the casting process,
cleaning and finishing the castings.
The two main processes upon which the present work is based
on are green sand mould process and shell mould process.
Green sand mould process utilizes a mould made of
compressed or compacted moist sand packed around a wood
or a metal pattern. Whereas shell mould process is an
expendable mould casting process that uses a resin covered
sand to form the mould. Sand used in both the processes has
different characteristics which has impact on final mould as
well as finishing. Sand used in green sand mould process
contains high moisture content whereas shell mould process
uses fine-grained high purity sand along with resin.
Accordingly the castings taken out will be less smoothly
finished bearing rough surfaces in green sand mould process
and fine finished castings in shell mould process. To match
with the increasing demand, industry concentrated on
changing the process and accordingly the machinery setups
which routed towards shell mould process from green sand
mould process.
In this paper, we describe analysis and experimentation of the
system for the production of castings which improves yield,
quality and delivery of castings and also reduction in rate of
rejection, raw materials and manual work. Analysis and
experimentation will be performed and results will be
compared.
2. RELATED WORK
There are many works carried out on castings and their types
[1] the casting liquid metals to produce solid objects is a
manufacturing process which has been practiced since many
years, with investment castings being one of the oldest known
metal shaping methods. The technique has tremendous
advantages in the production of quality components and the
key benefits of accuracy, versatility and integrity. In this work
incorporating organic fibres into the binder improved
performance and reduced shell production time and also shell
thickness is improved.[2]
Reports on an improved method to evaluate both the strength
and the permeability of ceramic shell specimens under high
temperature conditions. [3] In order to maintain safe testing
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conditions and use lower testing pressure, a spherical wax
model was used to prepare ceramic shells. Compressed air was
introduced into ceramic shell specimen held at 900 ◦C. Air
flow and pressure drop across the shell wall were measured
and hot permeability was calculated. Air pressure was
subsequently increased and recorded up to bursting point. A
hoop stress formula was used to calculate the hot strength
from the bursting pressure. This very simple method is easy to
implement in foundries.
3. PROCEDURE
As per customer requirements, foundries will manufacture
different grade of castings. Present work is carried out for SG
700/2 Grade.
Providing allowances, risers sprues etc drawing according to
the customer requirement is done.
3.1 Preparation of Moulds
AFS 75/78/80 Sand mixed with4-6% resin is weighed as per
requirement and required pattern is kept in the shell mould
machine. Sand is filled properly in the pattern and it is heated
to required temperature (usually 175-370∘C).using compressed
air shell moulds are cleaned and inspected for
damages[4].Moulds are heated to 180-200∘C for 30-45∘ C in
core oven to cure them to dark brown colour and cope over the
drag matching locating pins is placed.
Fig.1. Shell Mould Manufacturing Machine
Fig.2 Mould Produced
3.2 Preparation of Molten Metal
Molten metal is prepared using CRCA scrap, copper, Ferro
manganese, Ferro silicon, inoculants, calcium carbide, and
corbocoke as basic raw materials. First charge 40 –50
Kilograms of Cast Iron Boring to the bottom of the crucible.
Switch ON the induction furnace & charge the Solid Scrap
like Foundry Returns, Steel Scrap in orderly manner. Give full
Power and keep on poking the Charge with tarsteel & pig iron
for faster melting and for optimum Power utilization. Continue
to charge till furnace is 85% to its total capacity. Required
Carburizer, Ferro alloys to be charged as per calculation. Once
the molten metal bath attains approx.1350°C take the sample
to check the chemistry. Get the Spectro lab report if
composition achieved ok top up the furnace by adding returns,
otherwise dilute or add Ferro alloy/carburizer to make up the
composition, remove the slag using slagger and release the
metal for Magnesium treatment.
Magnesium treatment: Take-required percentage of
magnesium alloy and inoculation on the quantity of molten
metal in the alloy pit of treatment ladle place the tundish
cover.
Pour the metal from the furnace to the treatment ladle to get
react to the magnesium alloy to convert in to S.G.Iron molten
metal. Take the molten metal after treatment for pouring in the
same ladle or transferring to T spout ladle. Do post stream
inoculation while pouring & complete the pouring within the
stipulated time to avoid fading of magnesium. Take a sample
for microstructure and final chill sample for Spectro analysis.
Fig.3 Induction furnace
3.3 Shakeout and Degating
The solidified metal component is removed from the mould.
This process frees the casting from sand if attached. Degating
is the removal of the heads, runners, gates and risers from the
casting. Runners, gates and risers can be removed using
cutting torches, bandsaws or ceramic cut-off blades.
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3.4 Inspection and Fettling
A. First Stage Inspection
After knocking the castings from the moulds , the moulds are
inspected for mismatch, Blow Hole, Shrinkage, Short Pour,
Mould leak, Sand drop, Casting bulge, cold Shuts, under cut
etc., All castings are shot blasted / sand blasted first stage
inspection shall be carried out. On observation of the
following defects the castings are identified and
reject/reworked. Now-a-days automatic detectors are
developed for this purpose [4].
B. Second Stage Inspection
After 1st
stage inspection, Removal of riser neck, ingate area,
flow of area and other extra material on the casting is done
using hammer & cutting wheel. The knockout foundry returns
shall be moved to respective bin / locations. Second stage
inspection will be conducted and defective castings will be
reject/reworked.
C. Fettling
Inspected castings are ground smoothly to match the casting
surface. Grind the parting line completely. Remove defects
concerned to shrinkages[7] fins, sticky materials, sand and
scaling. Use proper equipments and tools to reduce fettling
cost. Under cuts shall be avoided.
3.5 Finishing
Finishing of castings is done using three types of CNC
machines. 3 main CNC machines used are horizontal, vertical
and Turning CNC. According to the need, castings are allowed
to any one machine and finished.
Fig.4. Finished castings
4. COMPARISON BETWEEN SG 700/2 AND 400/18
GRADE CASTINGS
As stated earlier this work is carried out considering SG 700/2
grade. Comparison of this with other grade is done in order to
study the difference between different grades. For this study
another grade is considered for i.e. 400/18 which shows much
more deviation from the grade considered.
4.1 Chemical Composition
Chemical composition of SG 700/2 Grade is graphically
represented as below. Minimum and maximum values of
copper, manganese, phosphor, silicon, copper and magnesium
is shown. In the same way chemical composition of SG 400/
18 grade is also shown graphically
Fig.5. Graphical representation of chemical composition of
SG 700/2Grade
Fig.6. Graphical representation of chemical composition of
SG 400/18 grade
4.2 Mechanical Properties
Mechanical properties [6] greatly affect the strength and
hardness of castings and hence the applications where they can
be used. Below two tables shows how mechanical properties
differ from grade to grade.
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
C Mn Si P Si Cu Mg
Min
Max
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
C Mn Si P Si Mg
Min
Max
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Volume: 03 Issue: 05 | May-2014, Available @ http://www.ijret.org 597
Table 1. Mechanical Properties of SG 700/2
HEA
T#
Yield
Stren
gth
Tensile
Strength(Kg
f/mm2
)
Elonga
tion %
Reduc
tion %
Hardness(
BHN)
MIN 42.84 71.40 2 - 225
MA
X
- - - - 305
Table 2. Mechanical Properties of SG 400/18
HEA
T#
Yield
Stren
gth
Tensile
Strength(Kg
f/mm2
)
Elonga
tion %
Reduc
tion %
Hardness(
BHN)
MIN 28.10 42.20 18 - 143
MA
X
- - - - 187
5. RESULTS AND DISCUSSION
Various parameters are considered and keeping the record of
production, Results from the green sand mould process are
considered with new process adopted in industry i.e. shell
mould process. 1) Increase in the Production rates leads to
beneficiary outcomes in any foundry which can be decided
by considering Yield of the Process which Was 65% by green
sand mould process and it is increased to 78% when castings
are produced by shell mould process.
Yield can be calculated by using the formula:
Casting weight
Pouring weight
I. Calculations
For green sand mould process, consider that 3kg molten metal
is poured to get castings out of which final castings weighed
were of 1.95kg , if we calculate yield for this calculation is as
fallows;
1.95 = 0.65, in percentage value we get 65% yield.
3
In shell mould process as we have little wastage casting
weight will be more, usually for a 3kg of molten metal, casting
weight will be around 2.35kg.When we calculate yield for the
set of castings which gave this readings we get, 2.35 = 0.7833,
which gives a percentage value of 78%
3
As shape, size, weight of castings produced will be different
according to the need it is required to produce different kinds
of castings.
These calculations are done considering the same casting in
two different processes. It is clear from the calculations that
for specified amount of molten metal weight of casting will be
more in shell mould process as wastage of metal will be less.
Fig 7. Graphical representation of yield
2) Customers will be satisfied by the timely delivery of
castings which can be increased up to 700/month by shell
mould process compared to green sand mould process.
This can be justified by the fact that in green sand mould
process 1box gives 4castings whereas in shell mould process
as there will be cakes arranged one above the other usually
which contains 10cakes/box which yields 40castings at once.
Green sand mould process:
1box 4 castings
Shell mould process:
1box 10cakes; 4*10=40 castings
3) Fine finishing of castings are done using CNC machines as
discussed earlier. Machining time by green sand mould
process was 45min/piece and now it is only 37min/piece so it
can be noted that around 8min/pc can be reduced/piece which
is a remarkable difference.
Above calculation is done for gear blank. Considerable
difference is achieved since the machining allowance provided
will be less in case of shell mould process as we get fine
finished castings, consider that it is required to produce a
casting with 100mm thickness, machining allowance given in
green sand mould process will be 108mm whereas it will be
105mm in case of shell mould process.
4) Productivity in kilograms /man/day was 30kilograms by
green sand mould process whereas it is 72kgs by new process
adopted which gives huge benefit.
5) Around 3.5% rejection of castings is achieved adapting
shell mould process as it was 8% before and reduced to 4.5%
later. . Rejection of castings depends upon their hardness, sand
drop, volatility, mismatch etc. These problems are very rare in
shell mould process and are common in green sand mould
process hence rejection rate will be more in green sand mould
process. When gear blanks are manufactured and supplied
using both processes above difference in rejection level is
noticed.
0 0.5 1
yield 1
yield 2
shell mould
process
green sand mould
process
x 100
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Volume: 03 Issue: 05 | May-2014, Available @ http://www.ijret.org 598
These results are graphically shown in figure below.
Fig 8.Graphical representation
Apart from these the main raw material used for casting
process is sand. Sand metal ratio used in green sand mould
process was 1:14 whereas this reduced drastically in case of
shell mould process which is 1:5 so it can be clearly noticed
that around 9% sand is reduced.
6. CONCLUSIONS
This paper provides brief idea about overall change in
production parameters of interest in a foundry when casting
production is shifted from green sand mould process to shell
mould process.
This study was done considering various parameters as
discussed above, it is because results of which clears provides
how and to what extent various parameters increased which
intern have great influence customer satisfaction and hence on
profit margins. Effort was made to improve quality, delivery
of castings, and yield in a foundry. Apart from these raw
materials required for the process is less and also manual work
comparatively can be reduced. All these improvements prove
to be beneficial for any foundry which wants to survive in
competitive market condition as well as to see growth in profit
margin.
REFERENCES
[1]. S. Jones, C.Yuan “Advances in shell Moulding for
Investment casting” 2003
[2]. S.Jones, Improved sol based ceramic moulds used for use
in investment casting.Ph.D.thesis, University of Birmingham,
Edgbaston
[3]. S.Amira, D.Dube, R.Tremblay “Method to Determine Hot
Permeability and Strength of Ceramic Moulds”2011
[4]. K. G. Swift, J.D.Booker "Manufacturing process selection
handbook”2013
[5]. Wong, B.K.; Sch of Eng.&Adv. Technol.,Sunderland
Univ;Elliot,M.P.;Rapley, C.W. "Automatic casting surface
defect recognition and classification”1995
[6]. Nieves, J.; S3Lab., DeustoTechnol.Found., bilbao, spain;;
santos,I.;Penya, Y.K,;Rojas, S more authors "Mechanical
properties prediction in high precision foundry production”
2009
[7]. Nieves, Javier;S3Lab.,Univ.ofDeusto ,Bilbao, Spain;
Santos,I.; Ugrate Pedrero, X.;Bringas, P.G. "Anomoly
detection of high precision foundries” 2011