TABLE OF CONTENT
Abstrak
i Abstract
ii Dedication
iii Acknowledgement
iv Table of Content
v List of Tables
ix List of Figures
xi List of Abbreviations
xiii
CHAPTER 1: INTRODUCTION 1
1.1 Background of the Project
1 1.2
Problem Statement 2
1.3 Objectives
3 1.4
Scope and Limitation 4
CHAPTER 2: LITERATURE REVIEW 5
2.1 Introduction to Casting
5 2.2
Advantages and Disadvantages of Casting 6
2.3 Casting Terminology
7 2.4
Design Consideration in Casting 10
2.4.1 Design of Section Geometry 10
2.4.2 Design of Gating System 14
2.4.3 Design of Pouring Basin 16
2.4.4 Sprue Design 16
2.4.5 Design of Runners and Gates 17
2.4.6 Design of Parting Plane 17
2.4.7 Design of Riser 18
2.4.7.1 Riser Shape
19 2.4.7.2
Riser Size 19
2.4.7.3 Positioning of Risers
19 2.4.8 Draft Consideration in Design
20 2.4.9 Design of Core and Cored Hole
21 2.5
Types of Moulds 23
2.6 Types of Patterns
24 2.6.1 Solid Pattern
24 2.6.2 Split Pattern
24 2.6.3 Skeleton Pattern
24 2.6.4 Match-plate Pattern
24 2.7
Casting Defects 25
2.8 Sand Casting
28 2.9
Types of Materials Used In Casting 30
2. 10.2.1 Aluminium-base Alloy
30 2.10 Castings Material Temperatures
31 2.11 Types of Sand Used In Casting
32 2.11.1
Green Sand 32
2.11.2 Dry Sand
32 2.11.3
Parting Sand 32
2.11.4 Facing Sand
33 2.11.5
Backing Sand 33
2.11.6 System Sand
33 2.12 Product Description
33 2.13 Function of the product
34 2.14 Product specification
34
CHAPTER 3: METHODOLOGY 35
3.1 Project Overview
37 3.2
Define the Problem Statement, Objective, Scope and Limitation 37
3.3 Literature Review
38 3.4
Product Design 38
3.4.1 Solidwork 38
3.4.2 Designing the product 40
3.4.3 Product Analysis 40
3.4.4 Mold Design 41
3.5 Machine and Specifications
41 3.5.1 Fused Deposition Modeling FDM
41 3.6
Design Concept Analysis 43
3.6.1 Analysis Software ANSYS 43
3.7 Design Selection
44 3.8
Sand Casting Process 45
3.8.1 Processs 45
CHAPTER 4: RESULT 50
4.1 Design Concept
50 4.2
Analysis Setup 52
4.3 Result of the Analysis
53 4.3.1 Design Concept 1 Mold A
53 4.3.1.1 Scaled Residuals
53 4.3.1.2 Static Pressure
54 4.3.1.3 Density
54 4.3.1.4 Total Temperature
55 4.3.1.5 Internal Energy
55 4.3.1.6 Turbulent Viscosity
56 4.3.1.7 Wall Shear Stress
57 4.3.1.8 Velocity Magnitude
57 4.3.1.9 Streamline
58 4.3.2 Design Concept 1 Mold B
59 4.3.3 Design Concept 1 Mold C
60 4.3.4 Design Concept 2 Mold A
61 4.3.5 Design Concept 2 Mold B
62 4.3.6 Design Concept 2 Mold C
63 4.3.7 Design Concept 3 Mold A
64 4.3.8 Design Concept 3 Mold B
65 4.3.9 Design Concept 3 Mold C
66
CHAPTER 5: DISCUSSION
