v
TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables ix
List of Figures x
List Abbreviations, Symbols and Nomenclatures xiv
CHAPTER 1: INTRODUCTION 1
1.1 Background of Study
1 1.2
Problem Statement 2
1.3 Objective
3 1.4
Scope of the Project 3
1.5 Report Structural
5 1.6
PSM Planning Flow Process 6
CHAPTER 2: LITERATURE REVIEW 7
2.1 Casting
7 2.1.1
Type of Casting 8
2.1.2 Fluid Flow
13 2.1.3
Flow Characteristic 15
2.1.4 Heat Transfer
15 2.1.5
Flow Pressure 16
2.1.6 Internal Energy
17 2.1.7
Flow Velocity 17
2.1.8 Turbulence Kinetic Energy
18 2.1.9
Wall Shear Stress 18
2.2 Sand Casting
18 2.2.1
Process of Sand Casting 19
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2.2.2 Component of Sand Casting
20 2.2.3
Sand 21
2.2.4 Defect of Sand Casting
21 2.3
Metal Metric Composite 23
2.3.1 LM6
24 2.3.2
Titanium Carbide 26
2.4 CAD Tool and Simulation and Analysis Software
27 2.4.1
SolidWorks 27
2.4.2 ANSYS Software
28 2.4.2.1
Computational Fluid Dynamic CFD 29
2.4.2.2. CFD Work principle
30 2.4.2.3
Advantages and Application 32
CHAPTER 3: METHODOLOGY 34
3.1 Flow Chart
34 3.2
Phase 1 36
3.2.1 Problem Identification
36 3.2.2
Literature review 36
3.3 Phase 2
37 3.3.1
Pattern Design 37
3.3.2 Mold Design
37 3.4
phase 3 39
3.4.1 Molten Metal Flow Simulation
39 3.4.2
Procedure of Flow Simulation Using ANSYS 41
3.5 Phase 4
54 3.5.1
Design Selection 54
3.5.2 Step in Pugh Concept Selection
55 3.5.2.1
Preparing the Selection Matrix 55
3.5.2.2 Rate the Concept
56 3.5.2.3
Rank the Concept 56
3.5.2.4 Combine and Improve the Concept
57 3.5.2.5
Select One or More Concept 57
3.5.2.6 Reflect On the Result and the Process
57
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3.6 Phase 5
58 3.6.1
Result and Discussion 58
3.6.2 Conclusion
58
CHAPTER 4: RESULT AND DISCUSSION 59
4.1 Design Sand Mould
59 4.1.1
Concept 1 60
4.1.2 Concept 2
62 4.1.3
Concept 3 64
4.1.4 Comparison among the Concept
66 4.2
Computational Fluid Dynamic Simulation Result CFD 67
4.2.1 Flow Pressure
68 4.2.1.1 Concept 1
69 4.2.1.2 Concept 2
71 4.2.1.3 Concept 3
73 4.2.1.4 Comparison Flow Pressure Between the mould
75 4.2.2
Internal Energy 76
4.2.2.1 Concept 1 76
4.2.2.2 Concept 2 77
4.2.2.3 Concept 3 78
4.2.2.4 Comparison Internal Energy Between the mould 79
4.2.3 Flow Velocity
80 4.2.3.1 Concept 1
81 4.2.3.2 Concept 2
83 4.2.3.3 Concept 3
85 4.2.3.4 Comparison Flow Velocity Between the mould
87 4.2.4
Cell Reynolds Number 88
4.2.4.1 Concept 1 89
4.2.4.2 Concept 2 90
4.2.4.3 Concept 3 91
4.2.4.4 Comparison Reynolds Number Between the mould 92 4.2.5
Turbulence Kinetic Energy 93
4.2.5.1 Concept 1 93
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4.2.5.2 Concept 2 95
4.2.5.3 Concept 3 97
4.2.5.4 Comparison Turbulence Kinetic Energy Between the Mould
99 4.2.6
Wall Shear Stress 100
4.2.6.1 Concept 1 100
4.2.6.2 Concept 2 101
4.2.6.3 Concept 3 102
4.2.6.4 Comparison Wall Shear Stress Between the mould 103 4.3
Concept Selection 104
4.3.1 Ranking Stage
104 4.4
Summary Result 106
CHAPTER 5: CONCLUSION AND RECOMMENDATION 108
