Comparison Of Sand Casting Surface Roughness And Dimension Accuracy Between Aluminium Silicon Carbide And Tin Silicon Carbide.
COMPARISON OF SAND CASTING SURFACE ROUGHNESS
AND DIMENSION ACCURACY BETWEEN ALUMINIUM
SILICON CARBIDE AND TIN SILICON CARBIDE
ABD HALEM BIN ABD RAZAK
B050810290
UNIVERSITI TEKNIKAL MALAYSIA MELAKA 2011
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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
COMPARISON OF SAND CASTING SURFACE ROUGHNESS AND
DIMENSION ACCURACY BETWEEN ALUMINIUM SILICON
CARBIDE AND TIN SILICON CARBIDE
This report submitted in accordance with requirements of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor of Manufacturing Engineering
(Manufacturing Process)
by
ABD HALEM BIN ABD RAZAK B050810290
FACULTY OF MANUFACTURING ENGINEERING 2011
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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: Comparison of Sand Casting Surface Roughness and Dimension Accuracy between Aluminium Silicon Carbide and Tin Silicon Carbide
SESI PENGAJIAN: 2010/2011 Semester 2 Saya ABD HALEM BIN ABD RAZAK
mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk
tujuan pengajian sahaja dengan izin penulis.
3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan pertukaran antara institusi pengajian tinggi.
4. **Sila tandakan (√)
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
Alamat Tetap:
NO 26, Jalan Desa Molek 12, Taman Desa Molek, Air Molek, 75460, Melaka.
Tarikh: 20 May 2011
Disahkan oleh:
PENYELIA PSM
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DECLARATION
I hereby, declared this report entitled “Comparison of Sand Casting Surface Roughness and Dimension Accuracy between Aluminum Silicon Carbide and Tin
Silicon Carbide” is the results of my own research except as cited in references.
Signature : ………....
Author’s Name : Abd Halem Bin Abd Razak
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APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Process). The members of the supervisory committee are as follow:
……… Principle Supervisor
……… Co- Supervisor
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ABSTRAK
Tuangan pasir adalah proses tuangan logam lebur yang akan dituang kedalam acuan. Dalam kajian ini, mengkaji antara aluminium silicon carbide dengan tin silicon carbide untuk mengetahui kekasaran permukaan dan ketepatan dimensi (mm). Objektif utama perlaksanaan kajian ini adalah untuk mengkaji kekasaran permukaan dan ketepatan dimensi (mm) manakah yang baik melalui proses tuangan pasir untuk alat pengeluaran. Dalam kajian ini, bahan utama yang digunakan ialah aluminium LM6 dan tin sebagai bahan utama dan ‘silicon carbide’ sebagai bahan yang digunakan untuk penetulang. Sebelum melakukan proses tuangan pasir, bahan ini akan di komposisikan antara aluminium dan tin dengan ‘silicon carbide’ mengikut pembolehubah yang ditetapkan. Daripada analisis antara aluminium dan tin akan mengkaji antara bahan yang berlainan akan mempengaruhi prestasi produk akhir dalam kontek ketepatan dimensi (mm) dan kekasaran permukaan.
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ABSTRACT
Casting process basically involves pouring molten metal into a mould cavity. In this study, aluminum and tin with reinforcement with silicon carbide to determine affected surface roughness and dimensional accuracy (mm). The main objective of the implementation of this study was to investigate the different material aluminium and tin reinforcement with silicon carbide on dimensional accuracy and surface roughness using sand casting for manufacturing equipment. In this study, the main material used is aluminum LM6 and tin as the main material and the silicon carbide as the material used to reinforcement. Before the process of sand casting, this material will be composition between aluminum and tin with the silicon carbide. From the analysis of aluminum and tin with material composition will be affect the performance of the final product in the context of dimensional accuracy (mm) and surface roughness.
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ACKNOWLEDGEMENT
Alhamdulillah and thank to Allah S.W.T. for giving me strength and ability to accomplish this project research successfully. I would like to take the utmost opportunity to express my sincere and gratitude to my supervisor, Prof. Dr. Mohd Razali Bin Muhamad and core supervisor, Mr Taufik who is always giving me supports and guidance throughout the year in completing this ‘Projek Sarjana Muda’. Besides that, thanks a lot to all lecturers and staffs of Faculty of Manufacturing Engineering.
Finally, to all my fellow friends who involves direct or indirectly that always stand strong beside me in giving opinions and supports throughout our relationship, I really thankful and appreciate it.
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DEDICATION
This thesis is dedicated to my parents Abd Razak Bin Md Yatim and Awa Bte Che Mat who introduced me to the joy of reading from birth, enabling such a study to take place today.
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TABLE OF CONTENT
Abstrak i
Abstract ii
Acknowledgement iii
Dedication iv
Table of Content v
List of Tables ix
List of Figures xi
List of Abbreviations xiv
1. INTRODUCTION 1
1.1 Background 1
1.2 Problem Statement 2
1.3 Objective 3
1.4 Scope of the Project 3
2. LITERATURE REVIEW 4
2.1 Casting 4
2.1.1 Introduction 4
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vi
2.1.3 The Sand Casting Process 7
2.1.4 Mould Design 14
2.2 Aluminium 15
2.2.1 Introduction 15
2.2.2 Aluminium Silicon Carbide 16
2.2.3 Aluminium Casting 17
2.3 Tin Properties 17
2.4 Metal Matrix Composite 19
2.5. Reinforcement 20
2.6 Surface Roughness 21
2.7 Dimension Accuracy 22
3. METHODOLOGY 28
3.1 Introduction 28
3.2 Flow chart methodology process 29
3.3 Mechanical Drawing Part 30
3.3.1 SolidWorks 30
3.3.2 Drawing Part 30
3.4 Fused Deposition Modelling (FDM) 31
3.4.1 Machine Specification 32
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vii
3.5 Material Preparation 34
3.6 Sand casting Procedure 35
3.6.1 Mould Design 36
3.6.2 Flow Chart of Step in Sand Casting 37
3.6.3 Step Casting Process 38
3.7 Measurement Equipment 42
3.7.1 Surface Roughness Measurement 42
3.7.2 Basic Specification 43
3.7.3 Dimension Accuracy 43
3.7.4 Coordinate Measuring machine (CMM) 45
3.7.5 Coordinate Measuring machine (CMM) Specification 45 3.7.6 Working Procedure Coordinate Measurement Machine (CMM) 46
4. RESULT 48
4.1 Introduction 48
4.2 Surface Roughness Result 48
4.2.1 Surface Roughness Analysis 57
4.3 Dimension Accuracy 59
4.31 Dimension Accuracy Analysis 62
5. DISCUSSION 63
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viii
5.2 Sand Properties 63
5.3 Pattern Design 64
5.4 Effect Material Composition 65
5.5 Effect Pouring 65
5.6 Effect Gating Systems 66
5.7 Impact Toughness Test 67
6. CONCLUSION AND FUTURE WORKS 71
6.1 Introduction 71
6.2 Conclusion of Research 71
6.3 Future Works 72
REFERENCES 73
APPENDICES
A. Gantt Chart PSM B APPENDIX B
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ix
LIST OF TABLES
2.1 Melting points of some metals 15
2.2 The characteristics of aluminium silicon Carbide 16
2.3 The characteristics of tin 18
2.4 Summarization of the research 24
3.1 400mc specifications (Stratasys, FDM 400mc, system documentation) 32 3.2 Material composition with silicon carbide percentage 34 3.3 Specification of Portable Surface Roughness Tester 43
SJ-301 for X-axis (drive unit)
3.4 Specification of Portable Surface Roughness Tester, SJ-301 for detector 44
3.5 Wenzel LH54 specifications 45
4.1 Aluminium Silicon Carbide result surface roughness 49 4.2 Tin Silicon Carbide result surface roughness 53 4.3 Summarization research on the surface roughness analysis in sand casting 58 4.4 The result aluminium silicon carbide data dimension 60 4.5 The result tin silicon carbide data dimension 61 4.6 Summarization research on the dimension accuracy analysis in 62
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x
5.1 The result Aluminium silicon carbide Toughness testing 69 5.2 The result Tin silicon carbide Toughness testing 69
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xi
LIST OF FIGURES
2.1 Pouring molten metal into mould 5
2.2 Two moulds ready for pouring and one left open to show care 8 2.3 A mould, pattern and core box for simple casting 10
2.4 Procedure for making mould 10
2.5 Schematic illustration of sequence of operation for sand casting 11 2.6 Schematic illustration of typical riser-gated systems 13 2.7 Schematic illustration of sand mould, showing various features 14
3.1 Experiment methodology 29
3.2 Isometric projection drawing 30
3.3 3rd view projection drawing 31
3.4 FDM 400mc machine 32
3.5 Product using FDM machine 33
3.6 Silicon Carbide weighed with a weighing scale 34 3.7 The bell casting basic training equipment. 35 3.8 Methodology of step sand casting process 37
3.9 Patt ern using FDM machine 38
3.10 Core plat e 38
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3.12 Cope after ramming with sand and removing pattern, spure, and risers 39
3.13 Drag plate pattern 39
3.14 Process drag removing pattern 40
3.15 Drag after removing pattern 40
3.16 Core and drag will with plaid pattern 40
3.17 Core and drag assemble 41
3.18 The molten metal is then poured into the mould 41
3.19 The part is allowed to sit and cool 42
3.20 The part is removed from mould 42
3.21 Portable Surface Roughness Tester, Mitutoyo SJ-301 43 3.22 Coordinate Measuring Machine (CMM) Wenzel LH54 45
4.1 Measurement surface roughness using Portable Surface Roughness 49 Tester, Mitutoyo SJ-301
4.2 Result testing 1 aluminium silicon carbide surface roughness 50 4.3 Result testing 2 aluminium silicon carbide surface roughness 50 4.4 Result testing 3 aluminium silicon carbide surface roughness 51 4.5 Result testing 4 aluminium silicon carbide surface roughness 51 4.6 Result testing 5 aluminium silicon carbide surface roughness 52 4.7 Result testing 1 tin silicon carbide surface roughness 54 4.8 Result testing 2 tin silicon carbide surface roughness 54 4.9 Result testing 3 tin silicon carbide surface roughness 55
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4.10 Result testing 4 tin silicon carbide surface roughness 55 4.11 Result testing 5 tin silicon carbide surface roughness 56 4.12 Measurement dimension accuracy using Coordinate Measure 59
Machine (CMM)
5.1 Effect the sand mould in core and drag 64
5.2 Sample Impact toughness testing 67
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LIST OF ABBREVIATIONS
ABS - Acrylonitrile Butadience Styrene
Al - Aluminum
AlSic - Aluminum Silicon Carbide BOM - Bil of Material
CMM - Coordinate Measurement Machine CO2 - Carbon Oxide
FDM - Fused Deposition Machine LCD - Liquid Crystal Display
Mm - Millimeter
MMC - Metal Matrix Composite m/s - meter per second
Pa - Pascal
Ra - Roughness Average RSM - Root Mean Square SiC - Silicon Carbide SiO2 - Silicon Oxide TinSic - Tin Silicon Carbide
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1
CHAPTER 1
INTRODUCTION
1.1 Background
In this study, production tool is produced by using sand casting process. The important element in this study is how to build the accurate dimension accuracy production tool using and surface roughness by sand casting process. The conceptual model of part is created by using software SolidWorks for produce pattern. Typically, these processes involve the design of the production tool part using Solid Works because easy for the designer to interpreted their design and not only fitted with 2Dimensional axis only. Using SolidWorks, the design can be drawn in 3-dimensional (3D) and also drawn in full scale measurement.
The master pattern from SolidWorks and then transferred to Fused Deposition Machine (FDM) machine rapid prototype to create a final part. The pattern is made up from ABS material using FDM machine. The next process is sand casting process and is done by melt the actual master pattern in carbon dioxide (CO2) sand mold. The quality characteristic such as dimensional accuracy will be analyzed using Coordinate Measure Machine (CMM) and portable surface roughness tester.
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2
Apart from that, the reason to conduct this study is to compare the dimension accuracy and surface roughness between aluminum and tin material composition produced by sand casting. Several literature reviews, generally from published journal, are undertaken into this study to identify the significant effect of dimensional accuracy and surface roughness of produced parts. Casting process is the basically involves pouring molten metal into a mould cavity where upon solidification its takes the shape of cavity. A wide variety of the product can be cast. This process is capable of producing intricate shape in one piece including those with internal cavities. The fundamental is essential for the production of good quality and economical casting and for establishing proper technique for mould design casting practice. Solidification and cooling of metals in the mould are effected by several factors including the metallurgical and thermal properties of the metal. The type of mould also has important influence because it affects the rate of cooling of the metal in the mould (Kalpakjian and Schmid, 2006). The reinforced with silicon carbide (SiC) particulates between aluminium and tin produce a homogenous distribution of reinforcement in the matrix. While other methods of production like casting have the problems of reinforcement segregation and clustering, interfacial chemical reactions, high localized residual porosity and poor interfacial bonding (Khairaldien et al.,
2007).
1.2 Problem Statement
This study is aimed to find out the answer for the following question which is the dimension accuracy using sand casting produced part is not same as the master pattern. Dimensional accuracy is very important when sand casting is applied because if the final product not accurate, so the product will malfunction. However, the study review of casting process by using different material aluminium and tin reinforcement silicon carbide with indentifying the effect surface roughness. The manufacturer needs to recreate back the casting process and it will cost more for making the product.
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3 1.3 Objective
The objectives of this research are:
i. To investigate the different material aluminium and tin reinforcement with silicon carbide on dimensional accuracy and surface roughness using sand casting.
ii. To identify the effect dimension accuracy and surface roughness using sand casting.
1.4 Scope of the Project
This research will emphasize on the casting quality with surface roughness and dimensional accuracy of aluminium and tin with reinforcement silicon carbide in sand casting. The effect of surface roughness and dimensional accuracy according to the different material through sand casting process with studied and explained in this research. In this research used aluminium and tin reinforced with silicon carbide composites in different structural applications. Other than that, production tool is an important component of manufacturing which contributes to a process of designing and developing the tools, methods and techniques necessary to improve manufacturing efficiency and productivity.
The scopes study this project about the:
a) Material composition (Aluminium and Tin with reinforcement Silicon carbide)
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4
CHAPTER 2
LITERATURE REVIEW
2.1 Casting
2.1.1 Introduction
In this study, the basic casting principle of the most popular methods of producing parts in metal is by casting. Casting is the process of forming objects by pouring liquid metal into a cavity having the same shape as the finished article (the mould), and then letting it solidify and cool. When removed from the mould, the casting produced should be an exact replica of the mould (Frederick, 1996).
The casting process is little metal is wasted. In most early casting processes many which are still used that be must destroyed in order to remove the product after solidification. The used for permanent mould, which could be used to produce component in endless quantities, was the obvious alternative (Edward, 2003).
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5
The casting and solidification process involve pouring and cooling the liquid metal. The information of the heat transfer and fluid mechanic occurring during pouring and cooling is also necessary (Bibby and Beddoes, 2003). Often, the casting process are important and extensively used manufacturing methods, enabling the production of very complex or intricate parts in nearly all types of metals with high production rates, average to good tolerances and surface roughness, and good material properties (Alting, 1994).
Figure 2.1: Pouring molten metal into mould (Parashar and Mittal, 2007).
2.1.2 Sand casting
In this study, the type of casting method used the sand casting technique process .In foundries; sand is used for making moulds. Natural sand found on the bed and banks of rivers provides an abundant source, although high quality silica sand is also mined. Sand is chemically SiO2 (silicon dioxide) in granular form. Ordinary river sand contains a contain percentage of clay, moisture, non-metallic impurities and traces of magnesium and calcium salts besides silica grains.
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LIST OF ABBREVIATIONS
ABS - Acrylonitrile Butadience Styrene
Al - Aluminum
AlSic - Aluminum Silicon Carbide
BOM - Bil of Material
CMM - Coordinate Measurement Machine
CO2 - Carbon Oxide
FDM - Fused Deposition Machine
LCD - Liquid Crystal Display
Mm - Millimeter
MMC - Metal Matrix Composite
m/s - meter per second
Pa - Pascal
Ra - Roughness Average
RSM - Root Mean Square
SiC - Silicon Carbide
SiO2 - Silicon Oxide
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1
CHAPTER 1
INTRODUCTION
1.1 Background
In this study, production tool is produced by using sand casting process. The important element in this study is how to build the accurate dimension accuracy production tool using and surface roughness by sand casting process. The conceptual model of part is created by using software SolidWorks for produce pattern. Typically, these processes involve the design of the production tool part using Solid Works because easy for the designer to interpreted their design and not only fitted with 2Dimensional axis only. Using SolidWorks, the design can be drawn in 3-dimensional (3D) and also drawn in full scale measurement.
The master pattern from SolidWorks and then transferred to Fused Deposition Machine (FDM) machine rapid prototype to create a final part. The pattern is made up from ABS material using FDM machine. The next process is sand casting process and is done by melt the actual master pattern in carbon dioxide (CO2) sand mold. The quality characteristic such as dimensional accuracy will be analyzed using Coordinate Measure Machine (CMM) and portable surface roughness tester.
(3)
2
Apart from that, the reason to conduct this study is to compare the dimension accuracy and surface roughness between aluminum and tin material composition produced by sand casting. Several literature reviews, generally from published journal, are undertaken into this study to identify the significant effect of dimensional accuracy and surface roughness of produced parts. Casting process is the basically involves pouring molten metal into a mould cavity where upon solidification its takes the shape of cavity. A wide variety of the product can be cast. This process is capable of producing intricate shape in one piece including those with internal cavities. The fundamental is essential for the production of good quality and economical casting and for establishing proper technique for mould design casting practice. Solidification and cooling of metals in the mould are effected by several factors including the metallurgical and thermal properties of the metal. The type of mould also has important influence because it affects the rate of cooling of the metal in the mould (Kalpakjian and Schmid, 2006). The reinforced with silicon carbide (SiC) particulates between aluminium and tin produce a homogenous distribution of reinforcement in the matrix. While other methods of production like casting have the problems of reinforcement segregation and clustering, interfacial chemical reactions, high localized residual porosity and poor interfacial bonding (Khairaldien et al.,
2007).
1.2 Problem Statement
This study is aimed to find out the answer for the following question which is the dimension accuracy using sand casting produced part is not same as the master pattern. Dimensional accuracy is very important when sand casting is applied because if the final product not accurate, so the product will malfunction. However, the study review of casting process by using different material aluminium and tin reinforcement silicon carbide with indentifying the effect surface roughness. The manufacturer needs to recreate back the casting process and it will cost more for making the product.
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3 1.3 Objective
The objectives of this research are:
i. To investigate the different material aluminium and tin reinforcement with silicon carbide on dimensional accuracy and surface roughness using sand casting.
ii. To identify the effect dimension accuracy and surface roughness using sand casting.
1.4 Scope of the Project
This research will emphasize on the casting quality with surface roughness and dimensional accuracy of aluminium and tin with reinforcement silicon carbide in sand casting. The effect of surface roughness and dimensional accuracy according to the different material through sand casting process with studied and explained in this research. In this research used aluminium and tin reinforced with silicon carbide composites in different structural applications. Other than that, production tool is an important component of manufacturing which contributes to a process of designing and developing the tools, methods and techniques necessary to improve manufacturing efficiency and productivity.
The scopes study this project about the:
a) Material composition (Aluminium and Tin with reinforcement Silicon carbide)
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4
CHAPTER 2
LITERATURE REVIEW
2.1 Casting
2.1.1 Introduction
In this study, the basic casting principle of the most popular methods of producing parts in metal is by casting. Casting is the process of forming objects by pouring liquid metal into a cavity having the same shape as the finished article (the mould), and then letting it solidify and cool. When removed from the mould, the casting produced should be an exact replica of the mould (Frederick, 1996).
The casting process is little metal is wasted. In most early casting processes many which are still used that be must destroyed in order to remove the product after solidification. The used for permanent mould, which could be used to produce component in endless quantities, was the obvious alternative (Edward, 2003).
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5
The casting and solidification process involve pouring and cooling the liquid metal. The information of the heat transfer and fluid mechanic occurring during pouring and cooling is also necessary (Bibby and Beddoes, 2003). Often, the casting process are important and extensively used manufacturing methods, enabling the production of very complex or intricate parts in nearly all types of metals with high production rates, average to good tolerances and surface roughness, and good material properties (Alting, 1994).
Figure 2.1: Pouring molten metal into mould (Parashar and Mittal, 2007).
2.1.2 Sand casting
In this study, the type of casting method used the sand casting technique process .In foundries; sand is used for making moulds. Natural sand found on the bed and banks of rivers provides an abundant source, although high quality silica sand is also mined. Sand is chemically SiO2 (silicon dioxide) in granular form. Ordinary river sand contains a contain percentage of clay, moisture, non-metallic impurities and traces of magnesium and calcium salts besides silica grains.