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 xiii
CHAPTER 1: INTRODUCTION 1
1.1 Background of Project
1 1.2
Problem Statement 3
1.3 Objective
3 1.4
Scope of Project 3
1.5 Synopsis of the Report
4
CHAPTER 2: LITERATURE REVIEW
2.1 Casting Technology
6 2.1.1
Sand Casting 7
2.1.2 Patterns
9 2.1.2.1
Pattern Material 10
2.1.3 Cores
12 2.1.4
The Mold 12
2.1.4.1 Elements of a Gating System
14 2.1.5
Sand 16
2.1.6 The Sand Casting Operation
17 2.2
Mould Filling 18
2.2.1 Conduction
23 2.2.2
Convection 24
vi 2.3
Natural fibre 25
2.3.1 Oil Palm Empty Fruit Bunch OPEFB
26 2.4
Summary 28
CHAPTER 3: METHODOLOGY
3.1 Stage of the Project
29 3. 2
Stage 1 – Design Planning 32
3.2.1 Indentify Problem
32 3.2.2
Literature Review 32
3.3 Stage 2 - Design Generation
33 3.3.1
Concept Sketching 33
3.3.2 CAD Modelling
33 3.3.3
Material Selection 34
3.3.4 Constraint and Boundaries
36 3.4
Stage 3 - Design Simulation 37
3.4.1 Simulation
37 3.4.2
Setting of ANSYS Flow Fluent 37
3.4.2.1 Geometry 38
3.4.2.2 Mesh 39
3.4.2.3 Setup 40
3.4.2.4 Solution 47
3.4.2.5 Results 50
3.4.3 Results
52 3.5
Stage 4 - Design Selection 53
3.5.1 Design Analysis and Discussion
53 3.6
Stage 5 - Design Presentation 54
3.6.1 Presentation
54 3.6.2
Conclusion and Recommendation 54
CHAPTER 4: RESULT AND DISCUSSION
4.1 Design of Sand Mould
51 4.1.1
Design Concept 1 56
4.1.2 Design Concept 2
57
vii 4.1.3
Design Concept 3 58
4.1.4 Design Concept 4
60 4.2
Molten Flow Simulation Results FLUENT 61
4.2.1 Flow Velocity Magnitude in Mould
61 4.2.1.1 Design Concept 1
62 4.2.1.2 Design Concept 2
63 4.2.1.3 Design Concept 3
65 4.2.1.4 Design Concept 4
66 4.2.1.5 Comparison between Design Concepts
68 4.2.2
Internal Energy 69
4.2.2.1 Design Concept 1 70
4.2.2.2 Design Concept 2 71
4.2.2.3 Design Concept 3 72
4.2.2.4 Design Concept 4 74
4.2.2.5 Comparison between Design Concepts 76
4.2.3 Static Pressure 77
4.2.3.1 Design Concept 1 78
4.2.3.2 Design Concept 2 79
4.2.3.3 Design Concept 3 81
4.2.3.4 Design Concept 4 82
4.2.3.5 Comparison between Design Concepts 84
4.2.4 Turbulent Kinetic Energy
85 4.2.4.1 Design Concept 1
86 4.2.4.2 Design Concept 2
87 4.2.4.3 Design Concept 3
89 4.2.4.4 Design Concept 4
90 4.2.4.5 Comparison between Design Concepts
92 4.2.5
Wall Shear Stress 93
4.2.5.1 Design Concept 1 93
4.2.5.2 Design Concept 2 94
4.2.5.3 Design Concept 3 95
4.2.5.4 Design Concept 4 96
4.2.5.5 Comparison between Design Concepts 97
viii 4.2.6
Cell Reynolds Number 98
4.2.6.1 Design Concept 1 99
4.2.6.2 Design Concept 2 100
4.2.6.3 Design Concept 3 101
4.2.6.4 Design Concept 4 102
4.2.6.5 Comparison between Design Concepts 103
4.3 Summary of Results
104
CHAPTER 5: CONCLUSION AND RECOMMENDATION
