Surface Roughness of Casted LM6 Using Natural Fibre Sand Casting Mould

2014 ◽  
Vol 903 ◽  
pp. 78-82
Author(s):  
Mohammad Hafizudin ◽  
Taufik ◽  
Mohd Razali ◽  
Nurul Farah
Keyword(s):  
Surface Roughness ◽  
Casting Process ◽  
Natural Fibre ◽  
Sand Casting ◽  
Silica Sand ◽  
Empty Fruit Bunch ◽  
The Third ◽  
Kenaf Fibre ◽  
Length Range ◽  
Sand Mould

This paper presents the investigation of sand casting process in natural fibre reactions which is utilized kenaf fibre and empty fruit brunch fibre (EFB) in order to reinforce the silica sand casting mould. The investigation was carried out on selecting sand mould which mixture with natural fibre. As a result of surface roughness of kenaf fibre mixed with silica sand, empty fruit bunch fibre mixed with silica sand and silica sand for sand mould was evaluated. The comparison of these three types of sand mould for surface roughness are analysed by using portable surface roughness tester. Technique of mixing the natural fibre and silica sand was presented. The mould was prepared using similar volume of natural fibre between kenaf fibre and empty fruit bunch fibre. The ratio of natural fibre for two type of sand fibre mould using 100 g of natural fibre and 1 kg of silica sand. The third sand mould using only 3.3 kg of silica sand without mixed with natural fibre. Total weight of three type of sand mould is 3.3 kg. Besides, this investigation was employed with 3 mm to 5 mm length range of natural fibre and mixture mutually with silica sand. The addition of natural fibre in the sand casting mould was significantly absorbing the heat of molten metal to the surrounding. As a result, the utilization of kenaf fibre and EFB fibre for sand mould were significant on improving the surface roughness of casted LM6 material.

OPTIMISATION OF SAND CASTING PROCESS FOR IMPELLER USING TAGUCHI METHODOLOGY

2020 ◽  
Vol XVII (2) ◽  
pp. 23-33
Author(s):  
Faisal Hafeez ◽  
Salman Hussain ◽  
Wasim Ahmad ◽  
Mirza Jahanzaib
Keyword(s):  
Surface Roughness ◽  
Surface Defects ◽  
A356 Alloy ◽  
Casting Process ◽  
Sand Casting ◽  
Gate Length ◽  
Taguchi Methodology ◽  
Confirmatory Tests ◽  
Binder Ratio ◽  
Response Measures

This paper presents the study to investigate the effects of binder ratio, in-gate length and pouring height on hardness, surface roughness and casting defects of sand casting process. Taguchi methodology with L9 orthogonal array was employed to design the experimentation. Sand casting of six blade impeller using A356 alloy was performed and empirical models for all the above response measures were formulated. Confirmatory tests and analysis of variance results confirmed the accuracy of the model. Binder ratio was found to be the most significant parameter affecting casting surface defects and surface roughness. This was followed by pouring height and in-gate length.

scholarly journals Utilising Flowability Sensor for Green Sand Mould Characterisation

2020 ◽  
Vol 1 (1) ◽  
Author(s):  
Dheya Abdulamer ◽  
Abdulkader Kadauw ◽  
Jürgen Bast
Keyword(s):  
Compaction Pressure ◽  
Casting Process ◽  
Sand Casting ◽  
Green Sand ◽  
Optimum Parameters ◽  
Good Pattern ◽  
Sensor Signals ◽  
Sand Mould ◽  
The Cost ◽  
Non Destructive

In this work, an attempt has been made to improve the sand casting process by reducing the percentage of casting defects. The enhancement of the sand casting process is based on producing green sand castings with good pattern profiles and no failures at any complex ‎points during the separation process, handling and transportation. This work ‎introduces modified, non-destructive, direct tests for measuring sand mould ‎properties using sensor readings. ‎A new flowability sensor has been used to measure the time-dependent density, ‎distance-dependent mould hardness, and distance-dependent mould strength. The ‎sensor is able to detect sand motion at the desired points during the mould-making process. The live characterisation of the green sand mould is used to determine the optimum ‎parameters for the compaction process, reduction of the moulding time, and spent ‎energy, so that the cost of the moulding and casting process will be reduced.‎ It has been found that there is a linear relationship between the properties of the green sand samples and the sensor signals. The new method facilitates the measurement of sand properties and determines the most effective moulding parameters based on the flowability sensor readings. The resultant increases in both compactibility and compaction pressure improve mould hardness and mould strength.

Simulation Study on Kenaf-Fibre Polyester Composite and LM6 Material

2015 ◽  
Vol 761 ◽  
pp. 584-588
Author(s):  
Nurul Farah Adibah Mohd ◽  
Taufik Roni Sahroni ◽  
Mohammad Hafizudin Abd Kadir
Keyword(s):  
Tensile Strength ◽  
Simulation Study ◽  
Fibre Composite ◽  
Young Modulus ◽  
Casting Process ◽  
Natural Fibre ◽  
Distribution Data ◽  
Kenaf Fibre ◽  
Materials Used ◽  
Sandwich Model

This paper present the investigation of sandwich model in the view of its properties. The objective of this paper is to define the mechanical properties of LM6 model and sandwich model. In recent years, researchers have viewed polymer matrix composite (PMC) as a potential material to increase the overall performance of materials for various type of field. This paper focused on the sandwich design by using metal material as the skin. The simulation study by using SolidWorks software is the simulation process used in this research to determine the stress, displacement and factor of safety of the design base. The purpose of design analysis in this paper is to prove the distribution data of simulation by indicating the maximum and minimum value of the design. In this research, LM6 materials used as the skin to introduced the kenaf-fibre composite in the sandwich design. LM6 is aluminium casting alloy which has tensile strength until 190MPa and its ductility properties enable to modify the shape by using casting process. The natural fibre has been used in this paper is kenaf-fibre due to its high tensile strength at 930MPa with 53GPa for the young modulus value. Two models are design for simulation study which is LM6 model and kenaf-fibre-LM6 model. These are to found out the characteristic between these two models.

Multi Response Optimization of Green Sand Moulding Parameters Using Taguchi-DEAR Method

2019 ◽  
Vol 895 ◽  
pp. 1-7
Author(s):  
M.J. Sandeep ◽  
Patel G.C. Manjunath ◽  
Ganesh R. Chate ◽  
Mahesh B. Parappagoudar ◽  
Umesh M. Daivagna
Keyword(s):  
Casting Process ◽  
Silica Sand ◽  
Cow Dung ◽  
Green Sand ◽  
Pareto Analysis ◽  
Design Flexibility ◽  
Complex Shapes ◽  
Response Optimization ◽  
Sand Mould ◽  
Moulding Sand

Green sand casting is treated as the most versatile casting process due to their excellent design flexibility that offer complex shapes and ability to reclaim silica sand. The modern foundries are looking for alternate moulding materials to partially replace the high cost silica sand. Cow dung is a naturally available eco-friendly binding as well as additive material and is used to partially replace the silica sand. Improper choice of the combination of moulding sand variables, such as degree of ramming, percentage of cow dung, percentage of clay, and percent of water will affect the moulding sand properties and thereby quality of casting. In the present work, Taguchi method is employed to plan and conduct experiments. Pareto analysis of variance is performed to know the contribution of variables on the moulding sand properties (i.e. compression strength, permeability, loss-on-ignition). Taguchi DEAR method is used to determine the single optimal levels of input factors that enhances the performances of all the sand mould properties. Percent of clay and cow-dung found to be the most dominating factor towards all the sand mould properties.

Morphology of aluminium with nickel addition on sand casting process

2018 ◽  
Vol 1 (87) ◽  
pp. 13-17
Author(s):  
P. Puspitasari ◽  
R. Fauzan ◽  
T.L. Ginta ◽  
M. Mustapha ◽  
D. Puspitasari
Keyword(s):  
Mechanical Properties ◽  
Grain Boundary ◽  
Casting Process ◽  
Sand Casting ◽  
Silica Sand ◽  
Phase Identification ◽  
Al Alloy ◽  
Simple Route ◽  
Ni Alloy ◽  
Nickel Addition

Purpose: his research aimed to examine the morphology, elemental changes, and phase in the aluminium cast alloys with variations in nickel addition of 1%, 2% and 3%. Design/methodology/approach: Aluminium 98% was melted in sand casting process. The sand casting process was operated at 7000C and atmospheric pressure. The addition of nickel contain of 92.19% of its element. Specimens consist of 4 pieces Al-Ni with the size of 1 x 1 x 0.5 cm for morphological testing, while for phase identification testing consist of 4 pieces Al-Ni with the size of 1 x 1 x 2 cm. The morphological testing was performed using FEI Inspect S50 Scanning Electron Microscope (SEM) and the phase characterisation was conducted using Nikon ME5 Optical Microscope. Findings: The results showed that the addition of 1% nickel in the aluminium cast product could affect the morphology in granular shape with as similar size, at 2% nickel addition also has granular shape, while at 3% of nickel addition, the morphology of Al-Ni was in elongated shape. Phase identification of Al-Ni cast alloy shows that there were Al matrix with nickel that spread in grain boundary of Al. By increasing the percentage of nickel, it shows that the nickel dominated the grain boundary of Al. These results shows that Al-Ni alloy can be produced at simple route on sand casting process. Research limitations/implications: Sand casting process with 80% silica sand, 10% bentonite, 5% water. Raw material of aluminium contains of 92-99% of purity. Nickel as addition element contain of 90-92% purity. Practical implications: The addition of nickel should be prepared wisely in term of the calculation of alloying treatment because it will effect the mechanical properties of Al alloy itself. This research can be improved by varying the temperature of casting process, variation of nickel percentage, and observation of mechanical properties of Al-Ni alloy. Originality/value: Simple route of making Al-Ni alloy using sand casting method in laboratory and also the observation of nickel addition in aluminium matrix as the result of casting product.

scholarly journals Experimental and simulation analysis on multi-gate variants in sand casting process

2021 ◽  
Vol 62 ◽  
pp. 119-131
Author(s):  
I. Rajkumar ◽  
N. Rajini ◽  
A. Alavudeen ◽  
T. Ram Prabhu ◽  
S.O. Ismail ◽  
...  
Keyword(s):  
Simulation Analysis ◽  
Casting Process ◽  
Sand Casting

EFFECT OF FIBRE TREATMENT ON LONGITUDINAL AND TRANSVERSE TENSILE PROPERTIES OF UNIDIRECTIONAL KENAF COMPOSITE

2015 ◽  
Vol 76 (11) ◽  
Author(s):  
Norhashidah Manap ◽  
Aidah Jumahat ◽  
Napisah Sapiai
Keyword(s):  
Tensile Properties ◽  
Strain Curve ◽  
Natural Fibre ◽  
Filament Winding ◽  
Fracture Mechanisms ◽  
Positive Effects ◽  
Transverse Tensile ◽  
Kenaf Fibre ◽  
Naoh Treatment ◽  
Kenaf Composites

Kenaf fibre has become one of the best candidates to be used as reinforcement material in polymer composite. However, the adhesion between natural fibre and polymer is weak due to different polarity of natural fibre and hydrophobic polymer. This affects the properties of the composite. One of the method to overcome this compatibility issue is by treating the fibre using sodium hydroxide (NaOH). This study is aimed to evaluate the effect of NaOH treatment on longitudinal and transverse tensile properties of kenaf composites using three different concentration (3, 5, and 7 wt. % NaOH). The kenaf composite test specimens were prepared using filament winding and vacuum bagging techniques. The 0o and 90o tensile tests were conducted in accordance to ASTM standard D3039 in order to obtain longitudinal and transverse tensile properties of treated and untreated kenaf composites. The fracture surfaces of the specimens were observed using scanning electron microscope in order to identify fracture mechanisms involved during tension. NaOH treatment on kenaf fibre resulted in a significant improvement in longitudinal tensile modulus, strength and failure strain. This also indicates an improvement in toughness property as this can be observed through a larger area under graph of tensile stress-strain curve. The SEM micrographs showed that the interfacial adhesion between kenaf fibre and epoxy matrix was improved when the kenaf fibre was treated using NaOH. Therefore, NaOH treatment give positive effects on longitudinal and transverse tensile properties of kenaf composites. Kenaf composite treated with 7wt% NaOH showed the highest tensile strength for both longitudinal and transverse fibre directions.

Thermal optimisation in the sand casting process

2001 ◽  
Vol 18 (3/4) ◽  
pp. 392-417 ◽  
Author(s):  
R.W. Lewis ◽  
M.T. Manzari ◽  
D.T. Gethin
Keyword(s):  
Casting Process ◽  
Sand Casting
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