UNIVERSITI TEKNIKAL MALAYSIA MELAKA - eprints.utem.edu.myeprints.utem.edu.my/11968/2/Design_And_Analysis_Of... · 2.1 Hierarchical classification of various casting processes 7 2.2

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

DESIGN AND ANALYSIS OF CASTED LM6 - TIC IN

DESIGNING OF PRODUCTION TOOLING

This report submitted in accordance with requirement of the Universiti Teknikal

Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Manufacturing Design) (Hons.)

by

ROHAYA BINTI DALI

B051010165

880116 – 09 – 5194

FACULTY OF MANUFACTURING ENGINEERING

2013

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: Design and Analysis of Casted LM6-Tic in Designing of Production Tooling SESI PENGAJIAN: 2012/13 Semester 2

Saya ROHAYA BINTI DALI

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 Malaysiasebagaimana yang termaktub

dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan

oleh organisasi/badan di mana penyelidikan dijalankan)

(TANDATANGAN PENULIS)

Alamat Tetap:

NO. 6, BLOK 1A,

FELDA RIMBA MAS,

02100, PADANG BESAR, PERLIS.

Tarikh: _________________________

Disahkan oleh:

(TANDATANGAN PENYELIA)

Cop Rasmi:

Tarikh: _______________________

** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.

DECLARATION

I hereby, declared this report entitled “Design and Analysis of Casted LM6-TiC in

Designing of Production Tooling” is the results of my own research except as cited

in the references.

Signature :

Author’s Name : Rohaya binti Dali

Date : 19 June 2013

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 Design) (Hons.). The member of the

supervisory is as follow:

………………………………

(DR. TAUFIK)

i

ABSTRAK

Peralatan pengeluaran merupakan salah satu elemen penting dalam industri

pembuatan yang membantu dalam pengendalian sesuatu proses. Kebanyakan

peralatan pengeluaran pada masa kini adalah kurang berpotensi dari segi kekuatan,

berat, dan bahan yang digunakan untuk menghasilkan sesuatu peralatan memerlukan

kos yang tinggi. Untuk menyelesaikan masalah ini, satu pendekatan melalui analisis

campuran yang melibatkan 90% daripada aloi LM6 dan 10% daripada titanium

karbida untuk mengetahui prestasi campuran bagi menggantikan bahan-bahan yang

sedia ada dalam menyediakan peralatan pengeluaran. Tiga konsep rekabentuk acuan

dilukis menggunakan perisian “SolidWork 2010” dan kemudiannya dianalisa melalui

perisian ANSYS bagi mendapatkan keputusan persembahan campuran bahan

tersebut di mana pengaliran bendalir lebur dalam proses tuangan dianalisa melalui

“FLUENT” dan faktor keselamatan dianalisa melalui “Static Structural” berdasarkan

kepada parameter tekanan, halaju, tenaga dalaman, tenaga kinetik turbulen dan

tegasan ricih dinding. Pendekatan ini telah berjaya diuji dan hasil keputusan

menunjukkan campuran aloi LM6 dan titanium karbida adalah berkesan dari segi

pengurangan berat, menjadi lebih kuat, meningkatkan kecekapan di samping

mengurangkan kos bahan dan boleh diaplikasikn dalam aplikasi kejuruteraan.

ii

ABSTRACT

Production tooling is one of the important elements in the manufacturing industry

that help to facilitate the operation and to smooth the flow of the process. Most of the

current production tooling is less potential in terms of strength, weight, and materials

used to produce the tooling at a high cost. To solve this problem, an approach

through the analysis of a mixture involves 90% of LM6 alloy and 10% of titanium

carbide to find out the mixture performances to replace the existing materials in

preparing production tooling. Three mould design concept was illustrated using

SolidWork 2010 software and then analyzed by ANSYS software to obtain the

results of the mixture performances in which the fluid flow of molten in the casting

process analyzed via FLUENT and factors of safety (FOS) through Static Structural

analysis based on the parameter of pressure, velocity, internal energy, turbulent

kinetic energy and wall shear stress. This approach has been successfully simulated

and the results showed the mixture of LM6 alloy and titanium carbide was effective

in terms of less weight, stronger, increases the efficiency as well as reducing the cost

of materials and can be applied in engineering application.

iii

DEDICATION

Dedicated to my beloved mother and all my siblings for their support,

encouragement and understanding.

iv

ACKNOWLEDGEMENT

First and foremost, I would like to express my heartily gratitude to my

supervisor, Dr Taufik for his guidance and enthusiasm given throughout the progress

of this project.

My appreciation also goes to my family who has been so supportive and

understanding for all these years. Thanks for their encouragement, love and financial

supports that they had been given.

Not to be forgotten to all the respondents that made this project successful.

Thank you for their support and willingness to be part of this project.

Last but not least, my greatest appreciation dedicated to all of the lecturers

that had taught me for the whole semester I had been through. And lastly, great

appreciation to my course mates for our bittersweet memories. Thank you so much.

v

TABLE OF CONTENT

Abstrak i

Abstract ii

Dedication iii

Acknowledgement iv

Table of Content v

List of Tables xi

List of Figures x

List of Abbreviation, symbols and nomenclature xiv

CHAPTER 1 : INTRODUCTION 1

1.1 Introduction 1

1.2 Problem Statement 3

1.3 Objectives 3

1.4 Scope of project 4

1.5 Project planning 4

CHAPTER 2 : LITERATURE REVIEW 5

2.1 Casting 5

2.1.1 History 5

vi

2.1.2 Introduction 6

2.1.3 Types of casting 6

2.2 Sand casting 8

2.2.1 Introduction 8

2.2.2 Sand silica 9

2.2.3 Types of sand mould 10

2.2.4 Pattern 11

2.2.5 Sand casting features 11

2.2.6 Sand casting process 13

2.2.7 Design 14

2.2.7.1 General consideration for casting 14

2.2.7.2 Casting consideration 15

2.2.7.3 Sand casting rules 20

2.2.7.4 Casting defect 22

2.3 Stir casting technique 23

2.4 Material selection 25

2.4.1 Introduction of metal matrix composite 25

2.4.2 LM6 alloy (A413.2) 26

2.4.2.1 Introduction 26

2.4.3 Titanium carbide 29

2.4.3.1 Introduction 29

2.4.3.2 Application of titanium carbide 31

vii

2.5 Production tooling 32

2.6 Engineering analysis tools 32

CHAPTER 3 : METHODOLOGY 33

3.1 Flowchart of research activity 33

3.2 Phase 1: Design planning 35

3.2.1 Proposal 35

3.2.2 Literature review and patent search 35

3.2.3 Review input 35

3.3 Phase 2: Design proposal 36

3.3.1 Design of production tooling 36

3.3.2 The engineering sketch and detailed design 36

3.3.3 Sand casting technique 37

3.3.4 Material 38

3.3.5 Parameters of production tools 38

3.3.6 Documentation stage 38

3.4 Phase 3: Design simulation 40

3.4.1 Design simulation using ANSYS 40

3.4.2 Setting of ANSYS CFX 41

3.4.2.1 Import geometry 41

3.4.2.2 Meshing 43

3.4.2.3 Setup 44

3.4.2.4 Results 49

viii

3.4.3 Setting of static structural analysis 50

3.5 Phase 4: Design selection 54

3.5.1 Design selection 54

3.6 Phase 5: Design presentation 54

3.6.1 Report writing 54

CHAPTER 4 : RESULTS AND DISCUSSION 55

4.1 Concept generation 55

4.1.1 Concept 1 56

4.1.2 Concept 2 56

4.1.3 Concept 3 57

4.2 Design selection 58

4.2.1 Simulation results 58

4.2.1.1 Static pressure 58

4.2.1.1.1 Comparison between concept 63

4.2.1.2 Velocity 63


4.2.1.3 Internal energy 69


4.2.1.4 Turbulence kinetic energy 74


4.2.1.5 Wall shear stress 79


ix

4.3 Static structural analysis 82

4.3.1 Total deformation 84

4.3.2 Equivalent (von-mises) stress 84

4.3.3 Thermal strain 85

4.3.4 Factor of safety 86

4.4 Summary of result 87

CHAPTER 5 : CONCLUSION AND FUTURE WORK 89

5.1 Conclusion 89

5.2 Recommendation 90

REFERENCES 91

APPENDICES

A Gantt Chart PSM 1

B Gantt Chart PSM 2

C Drawing of V-Block jig

D Drawing of Concept 1

E Drawing of Concept 2

F Drawing of Concept 3

x

LIST OF TABLES

2.1 Steps to the robust design of castings 15

2.2 Compositions of LM6 (%) 27

2.3 The properties of LM6 alloy 27

2.4 The properties of titanium carbide 30

3.1

4.1

4.2

Material properties

Ranking for three concepts

Summary of FOS

41

85

88

xi

LIST OF FIGURES

2.1 Hierarchical classification of various casting processes 7

2.2 Sequence of sand casting process 9

2.3

2.4

Schematic illustration of a sand mould, showing various features

Schematic illustrations of the sequence of operation for sand

casting

12

14

2.5

2.6

2.7

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

3.9

3.10

3.11

3.12

3.13

3.14

3.15

3.16

3.17

3.18

3.19

3.20

Temperature as a function of time for the solidification of pure

metals

Schematic illustration of three cast structure of metals solidified

in a square mould

Microstructure of Al-Si alloy

Flow chart of research activities

3D engineering drawing of production tool

2D engineering drawing of production tool

Mould design of concept 1



Import geometry into ANYSYS software

Rename the surface as inlet and outlet

Mesh setting

Result of meshing

Model setup

Materials setup

Velocity inlet setup

Velocity inlet setup (temperature)

Pressure outlet setup (momentum)

Pressure outlet setup (thermal)

Wall setup (thermal)

Dynamic mesh setup

Results

Streamline icon

16

16

29

34

36

37

39

39

40

42

43

43

44

44

45

46

46

47

47

48

48

49

49

xii

3.21

3.22

3.23

3.24

3.25

3.26

3.27

3.28

3.29

3.30

3.31

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

4.9

4.10

4.11

4.12

4.13

4.14

4.15

4.16

4.17

4.18

4.19

4.20

4.21

Chart icon

Starting of static structural analysis

Static structural-mechanical

Select material

Force

Thermal condition

Total deformation

Equivalent stress

Thermal strain

Safety factor (all bodies)

Safety factor (2 faces)

Isometric view design concept 1



Velocity vector coloured by static pressure of concept 1

Graph static pressure of concept 1

Velocity vector coloured by static pressure concept 2


Velocity vector coloured by static pressure of concept 3


Graph comparison of static pressure and concept

Velocity vector coloured by velocity magnitude of concept 1

Graph velocity magnitude of concept 1






Velocity vector coloured by the internal energy of concept 1

Graph internal energy of concept 1



49

50

51

51

52

52

53

53

53

53

54

56

57

57

59

59

60

61

62

62

63

64

65

66

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68

68

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70

71

72

72

xiii

4.22

4.23

4.24

4.25

4.26

4.27

4.28

4.29

4.30

4.31

4.32

4.33

4.34

4.35

4.36

4.37

4.38

4.39

4.40

4.41

4.42



Graph comparison of internal energy and concept

Velocity vector coloured by the turbulence kinetic energy

concept 1

Graph turbulence kinetic energy of concept 1


concept 2



concept 3


Graph comparison of turbulence kinetic energy and concept

Velocity vector coloured by wall shear of concept 1



Graph comparison of wall shear and concept

Applied force 500N

Applied thermal condition 22°C

Total deformation

Equivalent (von-mises) stress

Thermal strain

FOS for two faces

FOS for all bodies

73

73

74

75

75

76

77

78

78

79

80

80

81

82

83

83

84

85

85

86

87

xiv

LIST OF ABBREVIATIONS, SYMBOLS AND

NOMENCLATURES

ANSYS - Analysis System

FEA - Finite Element Analysis

FEM - Finite Element Method

FOS - Factor of Safety

IGS - Initial Graphics Specification

LM6 - Aluminium Alloy LM6

MMC - Metal Matrix Composites

SiC - Silicone Carbide

Ti - Titanium

TiC - Titanium Carbide

A - Area

P - Pressure

ρ - Density of fluid

g - Gravitational constant

xv

v - Velocity

Q - Volume rate

h - Distance

c - Friction factor

Re - Reynold number

D - Diameter

η - Viscosity

C - Constant

3D - 3 Dimension

2D - 2 Dimension

1

CHAPTER 1

INTRODUCTION

This chapter explains what the entire project is about along with details on the

background, purpose of this project, problem statement, objectives to be achieved, scope

of project and project planning.

1.1 Introduction

Asgari and Wong (2010) stated that Malaysia has grown at an average rate of 7.8% in

the 1970s and 8.8% during 1987-1996, whereby the previous economic focus structure

is based on agriculture, industry and services have shifted to manufacturing which gives

an increase in the percentage shares of Gross Domestic Product (GDP) growth of 16.4%

in 1975 to 34.2% by 1996. However, according to Mohd Zainal et al. (2011), in recent

years, the Malaysian manufacturing companies, as part of its overall effort to remain

competitive. It is important for Malaysian companies to stay ahead of the competition in

which products demand is increasing from time to time and they need to improve the

level of their production.

2

Manufacturing industry in Malaysia mostly is based on automotive, food and drink,

clothing, construction, electrical and electronics, metal, oil, rubber and so on. However,

production tooling is one of the manufacturing industries also contributed to the

economic growth of the country. According to the Maccarini et al. (1991), the tool itself

can determine remarkable and unpredicted increases in the final cost of the product as a

consequence of its reduced efficiency.

The eutectic aluminium silicon alloy or LM6 alloy is the near-eutectic group of ed

silicon alloys has characteristics of low thermal expansion, excellent castability, high

corrosion resistance, high abrasive wear resistance, good weldability, good thermal

conductivity, and high strength at elevated temperatures (Hajjaj, 2007). In addition,

according to Sulaiman (2008), LM6 alloy is a eutectic alloy having the lowest melting

and the main composition is about 85.95% of aluminium and 11% to 13% of silicon.

The characteristic of titanium carbide which are wear-resistant, high temperature

strength and refractory properties, useful in some applications, as examples are skins of

space rockets, jet engine nozzles, combustion engines, radiation resistant first walls of

nuclear reactors, armoring jackets, machine armors, metalworking tools, production

tools and water-jet cutting nozzles. Due to its light weight, titanium carbide hard metals

will be successfully used for the constructions of armor jackets and armors for airspace

machines if compared with hard metals based on tungsten carbide (Jalabadze et al.,

2012).

According to Frankel et al. (2006), castings appear in more than 90% of all

manufactured goods and in 100% of all manufacturing machinery. For example, the

multibillion-dollar metal casting industry serves the motor vehicle industry, industrial

machinery manufacturers, and electrical-power equipment industries. Miyake et al.

(2009) state that casting is one of the principal techniques in the field of industrial metal

production whereby the melted metal will poured through the gate and sprue runners

into a mould cavity and called as a traditional casting process.

3

However, the importance of the study is to examine the casted of LM6 and Tic to the

production tooling in terms of low weight as well as low waste.

1.2 Problem statement

Production tooling at the moment is very vibrant and developing as high demand and

positive feedback from users. There are several types of production tooling at present,

which are vise, clamping, jigs, fixtures, and so on. Currently, production tooling is based

on materials such as steel, metal, aluminium and so on. However, these materials are a

high cost and relatively heavy to be used in the production tooling. Therefore, a number

of improving materials such as metal matrix composite is to be used as an alternative

material to replace current materials in the context of reducing the weight and waste of

materials. The LM6 alloy and titanium carbide have better characteristic because both of

the material are a part of reinforced material. However, the combination of LM6 alloy

and titanium carbide is difficult to determine. Therefore, the study on the metal matrix

composite in casting process must be further investigated in order to determine the

performance of materials.

1.3 Objectives

These main purposes of this project are:

i) To investigate the LM6 Alloy and Titanium Carbide (TiC) in production tooling.

ii) To determine the factor of safety for casted LM6-Tic in production tooling.

iii) To design the production tooling by using LM6-TiC.

4

1.4 Scope of project

The production tooling is produced by implementing the sand casting process which is

expendable mould but permanent patent, in which it is used of stir casting technique.

The two materials of metal matrix composite which are LM6 (A413.2) and titanium

carbide (Tic (IV) Carbide ALDRICH -325 mesh.98%) are used by mixed with

percentage of 90 percent of LM6 and 10 percent of titanium carbide. Metal matrix

composite acts as a fluid to form a pattern and sand silica acts as a solid material that

serves as a mould in the analysis process later. In this project, a V-block jig acts as

pattern of production tooling and drawn using SolidWork 2010. Only one pattern of

production tooling is used however will be applied to three different concepts of mould

pattern. The temperature rise or drop, pressure, mass flow rate and others analysis were

carried out using ANSYS (Fluent) software. However, the Static Structural Analysis is

used to determine the factor of safety (FOS).

1.5 Project Planning

Two Gantt Charts will be created in order to show the planned schedule for PSM 1 (refer

Appendix A) and PSM 2 (refer Appendix B) progress that function as guidelines to

ensure the project complete at the right time.

5

CHAPTER 2

LITERATURE REVIEW

This chapter states about the data information gathered from previous research based on

several sources that consist of journals, conference, books, and articles about the design

and analysis of casted LM6-TiC in designing of production tooling. The topic that

contains in this chapter consist of casting, sand casting, production tooling, metal matrix

composite, LM6 alloy, titanium carbide, Solid Work 2010 software, Engineering

Analysis Tools software and other related topic.

2.1 Casting

2.1.1 History

According to Ravi (2004), one of the earliest castings is a bronze dancing girl which he

is 11 cm that was found at Mohenjo-Daro around the date of 3000 BC. An example of

metallurgical science in the 5th century is the Iron Pillar of Delhi which the dimension

of 25 feet of height, 6 tonnes of weight and it is containing 99.72 percent of iron without

any rust. However, other existing casting and one of the oldest casting is a copper frog

6

that was found in Mesopotamia about the date of 3200 BC. The state of Kamakura that

located in Japan, about 1252 AD, some other casting product which is a colossal statue

the Great Buddha completely produced using materials of tin. In the 14th century, he

mentioned that from India and Middle East to Europe by way of Portugese explorers, the

technology of casting was moved. Vannocio Biringuccio as the Head of Papal Foundry

in Rome (around 1500 AD) regarded to be a father of the foundry industry in the West

and had said “The art of casting… is closely related to sculpture … it is highly

esteemed… it is a profitable and skillful art and in large part delightful.”

2.1.2 Introduction

According to Gopinath and Balanarasimman (2012), the most ancient techniques used

for manufacturing metal parts is a metal casting process where it is defined as the

process to produce the desired shape of metal component parts by pouring the molten

metal into the prepared mould (of that shape) and then allowing the metal to cool and

solidify. It stated that the casting process is one of the fundamental types of

manufacturing any type of products. Basically there are several basic operations in the

process of casting that involves making the pattern, prepare the sand for moulding

process, melting of metal pouring of models, cooling, shakeout, fettling, heat treatment,

finishing and inspection. The main important role in the casting process is due to the

solidification of liquid metal in the mould cavity such a phase change from liquid to

solid which influence on the quality of the results in casting.

2.1.3 Types of casting

According to Ravi (2004), there are several numbers of the casting in industrial casting

process. Basically, the casting process is divided into three major process involves

7

expandable mould, permanent mould and special processes and the details are shown in

Figure 2.1.

Figure 2.1 Hierarchical classification of various casting processes (Ravi, 2004)

Mostly the casting practices classifications are related to materials of mould, pattern

production, processes of moulding, and methods of pouring the molten metal into a

mould and most categories of mould such as expandable moulds, permanent mould and

composite moulds (Kalpakjian and Schmid, 2010).

8

(a) Expendable mould

The moulds are usually made from sand, plasters, ceramics and similar materials and

mixed with a variety of binders in order to improve the characteristics and the

compositions consist 60% of sand, 7% of clay, and 3% of water. The expandable

mould or known as permanent-patent casting process is producing form a pattern,

where the mould is expandable however the pattern can be used again in order to

generate a number of moulds.

(b) Permanent mould

The mould is made of the metals due to at high temperature and retains its strength.

This type of mould will be used several times and design in simple in order to make

the casting easy to take out and used for another casting. The mould advantages

whereby it is better in heat conductors.

(c) Composites mould

The mould is made of various substances may be two or more that usually consist of

sand, graphite, and metal and it has a permanent and an expandable portion that used

to increase strength of mould, control the rates of cooling, and optimize the total

investment or cost of the casting process.

2.2 Sand Casting

2.2.1 Introduction

According to Saikaew and Wiengwiset (2012), sand casting still remains the most

widely used casting process even there are several new technology for metal casting and

this because it require less cost for raw materials, several sizes and composition for

different types of casting, and the sand mould can be recycled. It also mentioned that

9

sand casting is the one of the most versatile processes in manufacturing because it used

of most metals and alloys with high melting temperatures involves iron, copper, and

nickel. The steps of sand casting process are shown in Figure 2.2. Some types of process

such as grinding, turning, milling, and polishing can be go through in order to remove

the imperfections of surface or to add new features of casting product for better

finishing.

Figure 2.2: Sequence of sand casting process (Kalpakjian and Schmid, 2010)

2.2.2 Sand Silica

Sand is one of the important elements in sand casting process and use as the main mould

and core making material either for ferrous casting or non-ferrous casting. The physical

and chemical properties of sand play the important role in the casting process and it

Placing a pattern in sand mould

Incorporating a gating system

Remove pattern and fill mould cavity with molten metal

Allow metal to cool until solidifies

Break away the sand mould

Remove the casting

10

depends on the number of factors involves the metal and product being cast and also

consider about the type of binder used (British Geological Survey, (n.d)). According to

Kalpakjian and Schmid (2010), silica sand (SiO2) is mostly used as the mould material

for sand casting process. The process to cast sand consist of preparation mould around

the pattern, open the mould, remove the pattern, close the mould again and fill the

cavity left in the sand with molten metal. Once the metal solidified, the mould will shake

out and the duplicate pattern in metal is prepared (Ammen, 1979).

2.2.3 Types of sand mould

Three basic types of sand moulds in the sand casting process involves green-sand, cold-

box, and no-bake moulds' (Kalpakjian and Schmid, 2010).

(a) Green sand mould

This is the inexpensive method of making mould due to the sand can be reused and

most usual material used includes sand, clay and water. It is called as “green”

because the sand in the mould is moist and because the character is high strength,

generally used for large casting.

(b) Cold-box mould

This type of mould use binder which are organic and inorganic material that is

blended into the sand for greater strength in order to bond the grains chemically. It is

a more accurate dimension rather than green sand and it is high cost.

(c) No-bake mould

In this mould, the mixture of a synthetic liquid resin and sand will be hard at room

temperature without requiring heat and also known as cold-setting processes.

11

2.2.4 Pattern

According to Ammen (1979), a pattern can be defined as a shaped that form of wood or

metal around which sand is packed in the mould and right after the pattern is removed

the result cavity of casting is exactly like the shape of the project. It stated that in order

to reduce and avoid any damage to the mould, the pattern must be designed to be easily

removed and the pattern must be accurate in terms of the dimension and durable for the

use intended. According to Kalpakjian and Schmid (2010), metal shrinkage, permit

proper metal flow, and allow the pattern to be easily removed from the sand mould

should be available due to the pattern is the most critical aspect of the total casting

operation.

2.2.5 Sand Casting Features

There are many features in sand moulds, so that the system can function smoothly and

each feature has its own role to enable the system to be fully functional as shown in

Figure 2.3 (Kalpakjian and Schmid, 2010).

(a) Flask

It is functional as supporter to the mould that composed of cope (top) and drag

(bottom) that separated by parting line and if there additional parts are called cheeks

(more than two piece of mould).

(b) Pouring basin

Also known as pouring cup is functional as a guideline to pour molten metal into

moulds.

(c) Sprue

It is functional to flow the molten metal downward into the mould cavity.

12

(d) Runner system

It is responsible to flow the molten metal within the sprue into mould cavity by the

channel and also the gates as the inlet sources.

(e) Risers

There are two kinds of risers which are blind riser and open riser that useful for

casting due to it is supplying the additional molten metal as it shrinks during

solidification.

(f) Cores

Cores are put into the mould to make a hollow shape which is inserted that made

from sand. It is also applied on the outer of the casting to designing features such as

deep external pockets.

(g) Vents

Vents placed in moulds that serve to release the gases from the reaction between the

molten metal and the sand in mould and core. It is functional as exhaust air from the

mould cavity.

Figure 2.3: Schematic illustrations of a sand mould, showing various features

(Kalpakjian and Schmid, 2010).

13

2.2.6 Sand casting process

The cope and drag is closed, clamped, and weighted down when the mould has been

shaped and the cores already located in the right place in order to avoid the separation of

the mould when molten is poured into the mould cavity due to the exert pressure. It is

very important to know how to conduct sand casting in order to come out with a good

result and therefore whole steps of process in sand casting is shown in Figure 2.4


a) Generate design for the pattern using mechanical drawing.

b-c) Mounted patterns on plates equipped with pins for alignment.

d-e) Core halves produce by core boxes.

f) Assembled core by placing the cope pattern plate to the flask and attach inserts to

form the sprue and riser and secure by aligning pin.

g) The sand is rammed in the flask, and remove the plate and inserts.

h) Produce the drag with the same way of core by inserting the pattern.

i) The pattern, flask, and bottom board are reversed, and the pattern is withdrawn,

leaving the appropriate imprint.

j) The core is set in place within the drag cavity.

k) The mould is closed by placing the cope on top of the drag and securing assembly

with pins.

l) Casting is removed after metal solidifies.

m) The sprue and risers are cut off and recycled and the casting is cleaned, inspected,

and heat treated.

14

Figure 2.4: Schematic illustration of the sequence of operations for sand casting


2.2.7 Design

2.2.7.1 General Consideration for Casting

Table 2.1: Steps to the robust design of castings (Kalpakjian and Schmid, 2010).

Step Considerations

1 Design the shape of the part that easily cast.

2 Select a suitable casting process and materials involves the part, size,

15

mechanical properties and other related matters.

3 Locate the parting line of the mould in the part.

4 Locate and design the gates to allow uniform feeding of the mould cavity with

molten metal.

5 Select appropriate runner geometry of the system.

6 Locate mould features such as sprue, screen ad risers.

7 Make sure proper controls and good practice is in place.

2.2.7.2 Casting consideration

Basically, casting process starts by transferring the molten metal into the patterned

mould, which is patterned by the part that needs to be manufactured, thus allowing it to

solidify. The part then, removed from the mould. There are several important

considerations in casting operation in order to reduce the defects that greatly affect the

casting results (Kalpakjian and Schmid, 2010).

(a) Solidification of Metals

Throughout the solidification and cooling to ambient temperature of the metal, series

of event takes place. Molten metal that was poured into a mould will be influenced

for its size, shape, uniformity, and chemical composition of the grains which also

will influence the overall properties of the metal. Some several factors that causes of

the events are types of metal, the thermal properties, the connection between volume

and surface areas of casting in terms of the geometric form, and also the shape of the

mould.

i) Pure Metals

Pure metals have a clear melting (freezing) point and solidify at a constant

temperature that shown in Figure 2.5. The grain structure that develops in a casting

shows a cross section of a box-shaped mould as Figure 2.6a. The fine equiaxed

16

grains occur when the metal cools rapidly and produced shell as Figure 2.6b. While

columnar grains grown in orientation opposite to the direction of the heat transfer as

Figure 2.6c.

Figure 2.5: Temperature as a function of time for the solidification of pure metals


Figure 2.6: Schematic illustration of three cast structures of metals solidified in a square mould:

(a) Pure metals; (b) solid-solution alloys; and (c) structure obtained by using nucleating agents


17

(b) Fluid Flow

Fluid flow is one of important factor in the casting process whereby, the basic

principles for the fluid flow of the gating design applies the Bernoulli’s theorem and

mass continuity (Kalpakjian and Schmid, 2010).

i) Bernoulli’s Theorem

The principle conversation of the fluid elevation at any location in the system can be

expressed by:

(2.1)

Where;

h – Elevation above a certain reference level

p – Pressure at that elevation

– Density of the fluid

g – Gravitational constant

v – Velocity of the liquid at that elevation

Subscripts 1 and 2 represent two different locations in the system.

ii) Mass Continuity

The law of mass continuity states that the rate of flow is constant whereas the liquids

are incompressible and in a system with impermeable walls expressed in:

Q = A1v1 = A2v2 (2.2)

Where;

Q - Volume rate of flow (m3/s)

A – Cross sectional area of liquid system

v – Average velocity of the liquid in that cross-section

Subscripts 1 and 2 represent two different locations in the system.

18

iii) Sprue Design

Assuming that the pressure at the top of the sprue is equal to the pressure at the

bottom and there are no frictional losses, the relationship between height and cross

sectional area at any point in the sprue can be expressed by:

√

(2.3)

Where;

Subscript 1 denotes the top and 2 denotes the bottom of the sprue.

iv) Modelling

Modelling of mould filling obtained by the equation of the molten metal s’ velocity

while leaving the gate:

√ (2.4)

Where;

h – Distance from the sprue base to the liquid metal height

c – Friction factor

v) Flow characteristics

Fluid flow in gating systems has to consider the presence flow of liquid either

turbulence or laminar. To define the types of flow, Reynolds number (Re) is used as

expressed by:

(2.5)

19

Where;

v – Velocity of the liquid

D - Diameter of the channel

– Density of the liquid

- Viscosity of the liquid

(c) Fluidity of Molten Metal

Fluidity is defined as the capability of molten metal to fill the mould cavities

whereas the characteristics of molten metal and casting parameters are the two basic

factors considered (Kalpakjian and Schmid, 2010).

i) Viscosity

When the viscosity increased, the fluidity of molten metal decreased.

ii) Surface tension

High surface tension of the liquid metal can reduce the fluidity.

iii) Inclusions

Inclusions are insoluble and have a significant adverse effect on fluidity.

iv) Solidification pattern of the alloy

The way molten metal solidifies affect the fluidity.

v) Mould design

Fluidity of molten metal influenced based on the design and dimension of sprue,

runners, and the riser.

vi) Mould material and its surface characteristics

Higher thermal conductivity and rough surface of the mould caused the fluidity

molten metal decrease respectively.

20

vii) Degree of superheat

Superheat improves fluidity by delaying solidification.

viii) Rate of pouring

Fluidity decrease as the pouring rate of molten metal is reduced because of the

higher rate of cooling.

(d) Heat Transfer

In order to produce good results of casting, the heat transfer during the complete

cycle is another important consideration in metal casting (Kalpakjian and Schmid,

2010).

i) Solidification time

Starting stages of solidification, a thin skin begins to form at the relatively cool

mould walls which will increase with time can be expressed as an equation

(Chvorinov’s rule) below.

(2.6)

Where;

C – Constant

n – Value between 1.5 and 2

2.2.7.3 Sand Casting Rules

According to Campbell (2004), there are 10 rules in order to create a good casting as

shown details below:

21

(a) Start with a good quality melt

It is a requirement that either the process for the production and treatment of the melt

hall have been shown to produce good quality liquid, or melt should be demonstrated

to be of good quality.

(b) Avoid turbulent entrainment of the surface film on the liquid

Since for most liquid metal the maximum meniscus velocity is approximately 0.5

ms-1

, the flow of molten metal should not go too fast. This maximum velocity may

be raised in constrained by running systems or thin section of castings. This

requirement also implies that the liquid metal must not be allowed to fall more than

the critical height of a sessile drop of the liquid metal.

(c) Avoid laminar entrainment of the surface film on the liquid

This is the requirement that no art of the liquid metal front should come to a stop

prior to the complete filling of the mould cavity. This is achieved by the liquid front

being designed to expand continuously.

(d) Avoid bubble entrainment

No bubbles of air entrained by the filling system should pass through the liquid

metal into the mould cavity.

(e) Avoid core blows

No bubbles from the outgassing of cores or moulds should pass through the liquid

metal into the mould cavity.

(f) Avoid shrinkage

No feeding uphill in larger section thickness castings because of unreliable pressure

gradient and complications introduced by convection.

(g) Avoid convection

Avoid feeding uphill.

22

(h) Reduce segregation

Predict segregation to be within limits of the specification desired.

(i) Reduce residual stress

No quenching in water following solution treatment of light alloys.

(j) Provide location points

All castings to be provided with agreed location points for pickup for dimensional

checking and machining.

2.2.7.4 Casting defects

According to Campbell (2004), some types of defects can often resemble each other in

appearance and separating it is often difficult. There are several types of casting defect

explain details as below:

(a) Fin

Caused by cope and drag are cracked, flasks are wrecked, inadequate cope or drag

depth, and improperly rubbed at the bottom board.

(b) Rough surface

Caused by too coarse of sand, inadequate mould or core coating, finishing improper,

the pattern is soiled.

(c) Blows

Caused by the entrapped gas or air due to too hard rammed the sand, too wet of sand

and core, improperly dried green core, inadequate hydrostatic pressure and bars of

cope too close to the mould cavity.

23

(d) Pin hole

Caused by the surface pitted with pin holes

(e) Shrink

Caused by the depression on casting surface due to the metal shortage

(f) Gas porosity

Caused by the absorption of gasses in metal melting

(g) Hot tears

Caused by too high a hot strength of the core or moulding sand.

(h) Cold Shot

Caused by the mould cannot fill faster due to some problem of too cold metal poured

too slow and improper design of gating system.

(i) Misrun

Caused by cold metal, slow pouring, inadequate hydrostatic pressure, and humidity

(j) Run Out

Ramming sand caused a section of the mould being forced away from the pattern.

(k) Inclusions

Failure to keep the choke constant when pouring, moulding is soiled, and improper

blow out mould before closing

2.3 Stir Casting Technique

According to Prabu et al. (2006), the processing techniques of particulate reinforced

metal matrix composites consist of stir casting, liquid metal infiltration, squeeze casting,

24

spray decomposition and powder metallurgy. Stir casting is one of the techniques that

used for mixing the material of metal matrix composite along with natural fiber

composite and stirring to get the suitable dispersion (Naher et al., 2004).

However, according to Hashim (2001) generally stir casting method combine the

selected matrix material and reinforcement material to be melted and the dispersion of

the reinforcing material. Stirring causes to form a vortex where the reinforcing particles

are introduced through the side of the vortex. When the slurry viscosity is increased, the

air will entrap in the mould and it is very hard to remove.

On the other hands, according to Ravi et al. (2007), stir casting route is very economic

and commercial process in order to produce the large size shape of composite casting or

ingots that needs to be gone through secondary processing such as rolling, extrusion and

forging.

In addition, Prabu et al. (2006) stated that stir casting is a method that is preferable to be

applied in the industry due to simplicity, flexibility and most economic in fabricating

large sized of components. However, technology of casting having several technical

challenges currently exists and require attention are:

(a) Wettability between the particles and matrix.

The problem of the wetting of the ceramic by molten metal is one of surface

chemistry and surface tension. According to Hashim et al. (1999), the way to

improve wetting can be done through the rise up the solid surface energies, reduce

the liquid matrix alloy surface tension and reduce the particles-matrix interface.

(b) Porosity in the cast metal matrix composites.

According to Hashim et al. (1999), it is important to control mechanical properties of

material, porosity volume fraction, size in a cast metal matrix composite and

therefore the levels of porosity always be of minimum value. Porosity caused by gas

25

entrapment during mixing, evolution of hydrogen and shrinkage during

solidification. Basically the porosity cannot be avoided but it can be controlled

during the casting process.

(c) The reinforcement material and the matrix alloy chemical reactions.

According to Prabu et al. (2006), the microstructure and hardness of casting

influenced by the speed of stirring and time of stirring. When increased the stirring

speed, the non-uniformity occurred due to porosity, oxide skins, and gas formation at

higher stirring speeds. As a result, when the speed and time of the stirring process

increased, it resulted in a good hardness composite.

2.4 Material Selection

2.4.1 Introduction of Metal Matrix Composite

According to Kalpakjian and Schmid (2010), metal-matrix composite and ceramic-

matrix composites is derived from a mixture between two or more chemically distinct

and insoluble phases with a known interface. In an industry of aircraft, space vehicles,

satellites, offshore structures, piping, electronics, automobiles, boats, and sporting

goods, the application of these materials substantially improves the strength, stiffness,

and plastics creep resistance.

According to Koker et al. (2007), metal matrix composites (MMCs) have received great

attention due to their excellent properties whereby their characteristic which is high

specific strength, stiffness and wear resistance and capable of elevated temperature.

Therefore, MMCs nowadays applied in several applications of industry such as

connecting rods, automotive drive shafts, cylinder liners and brake rotors. Due to the

combination of its characteristic which are density, strength, stiffness, reliability and

26

structural efficiency, metal matrix composite becomes attractive to be implemented in

industry and consider as versatile engineering materials.

The advantages of a metal matrix composite rather than a polymer matrix due to the

characteristic which are the elastic modulus is higher, toughness, ductility, and at

elevated temperatures it higher resists. However, the material has restricted that consist

of the density is high and difficult in processing parts. Usually metal matrix composite is

aluminium, aluminium-lithium alloy, magnesium, copper, titanium, and superalloys


2.4.2 LM6 alloy (A413.2)

2.4.2.1 Introduction

As the name implies, silicon is the main alloying element in aluminium silicon alloys.

The material also known as LM6 alloy that sometimes called piston alloy is one of near-

eutectic group that having some common features such as low thermal expansion, very

good castability, elevated corrosion resistance, elevated abrasive wear resistance, good

weldability, good thermal conductivity, high strength at elevated temperatures and

excellent corrosion resistance. Based on the capability, they are able to implement in

industries such as applications of aerospace structure, industry of automobile,

applications of military, and some several industries that related (Hajjaj, 2007).

According to Sulaiman et al. (2008), the main composition of LM6 is composed

aluminium (85.95%), silicon (11% to 13% ) and Table 2.2 shows the details of the LM6

alloy composition.

27

Table 2.2: Compositions of LM6 (%)

The properties of LM6 alloy as shown in Table 2.3.

Table 2.3: The properties of LM6 alloy (CES Edupack (2010) and Hamouda et. Al (2007)).

Properties Description

UNS number A413.2

Density 2.65e3 kg/m^3

Price 1.76 USD/kg

Composition Al/12Si

Base material Al (aluminium)

Composition in detail Al (aluminium) 88%

Si (silicon) 12%

Young’s modulus 7.3e10 Pa

Shear modulus 2.7e10 Pa

Yield strength (elastic limit) 1.38e8 Pa

Tensile strength 2.89e8 Pa

Compressive strength 7.99e7 Pa

Flexural strength (modulus of rupture) 7.99e7 Pa

Elongation 0.0296

Hardness - Vickers 5.63e8 Pa

28

Fatigue strength at 10^7 cycles 4.08e7 Pa

Fatigue strength model (stress range) 3.55e7 Pa

Fracture toughness 2.65e7 Pa.m^0.5

Melting point 570 °C

Maximum service temperature (Tmax) 161 °C

Minimum service temperature (Tmin) -273 °C

Thermal conductivity 142 W/m.°C

Specific heat capacity 963 J/kg.°C

Thermal expansion coefficient 2e-5 strains/°C

Latent heat of fusion 3.88e5 J/kg

Electrical resistivity 4.65e-8 ohms. m

Solidus temperature 574 °C

Liquidus temperature 582 °C

The maximum amount of silicon in cast alloys is of the order of 22% to 24% Si.

However, increasing the amount of silicon may go as high as 40-50% Si if alloys made

by powder metallurgy as well as strength increases at the expense of ductility (Hajjaj,

2007).

The eutectic point for this alloy is at 12.6% Silicon. Hypereutectic aluminium silicon

alloys are those with silicon content more than 12.6% Si, whereas alloys containing less

than 12.6% Si are hypoeutectic aluminium silicon alloys. Figure 2.12 shows

microstructures of hypereutectic, hypoeutectic and eutectic aluminium silicon alloys

(Hajjaj, 2007).

29

Figure 2.7: Microstructure of Al-Si alloys: (a) Hypoeutectic (1.65-12.6 wt% Si) 150x;

(b) Eutectic (12.6% Si) 400x; (c) Hypereutectic (> 12.6% Si) 150x. (Hajjaj, 2007)

2.4.3 Titanium carbide

2.4.3.1 Introduction

Titanium, Ti is referring to name after the Greek god Titan is a silvery white metal

discovered in 1791s and commercially produced in 1950s. Even the titanium is one of an

expensive material, nevertheless the material mostly applied to industrial includes

aircrafts, jet engines, racing cars, golf clubs, chemical, petrochemical, marine

components, submarine hulls, armour plate, and medical applications due to the

characteristic of material which is the highest strength weight ratio and resist corrosion

at room (Kalpakjian and Schmid, 2010).

Titanium carbide content materials are used in rocket production, aircraft, nuclear power

and microelectronics industry. The probability of using titanium carbide is defined by a

complex variety of properties, one of them and the most important being structural

condition. The most promising is using of titanium carbide in micro-circuitry in the

electronic industry. Titanium carbide is one of the main constituents of hard metals. Role

of hard metals in modern technique cannot be overestimated, and, though tungsten

carbide is a leading in the industry of hard metals, but for many reasons titanium carbide

is also very attractive for using in this field. The main disadvantage of titanium carbide

30

is deficient of elasticity can be solved if the hard metals are on nanocrystalline level,

because physical-mechanical properties of nanocrystalline materials are much better

than of those with a crystalline structure. Nanocrystalline titanium carbide characterized

by excellent catalytic properties due to its light weight, titanium carbide hard metals will

be successfully used for the constructions of armour jackets and armour for airspace

machines if compared with hard metals based on tungsten carbide (Jalabadze, 2012).

According to Shyu and Ho (2006), metal matrix composites (MMC) such as carbides as

a reinforced material under development of whiskers, monofilaments, fibre and

particulates increasingly commercialized. As an example the application of

implementation metal matrix composite in Toyota industry is then used in aluminium

matrix composite in the development of diesel engine piston. Carbide-reinforced MMC

which is a 6061 aluminium matrix reinforced with a percentage of 25 volume % of SiC

particulate applied in flight production being another application of metal matrix

composites.

The properties of titanium carbide are tabulated in Table 2.4.

Table 2.4: The properties of titanium carbide (CES Edupack (2010) and Saha et. al (1990)).

Properties Description

Density 4.91 kg/m^3

Price 79.2 USD/kg

Composition Ti/.97C

Base material Ti (Titanium)

Composition in detail C (carbon) 0.97%

Ti (Titanium) 99%

Young’s modulus 4.35e11 Pa

Shear modulus 1.76e11 Pa

Yield strength (elastic limit) 2.93e8 Pa

31

Tensile strength 2.93e8 Pa

Compressive strength 2.93e9 Pa

Flexural strength (modulus of rupture) 3.52e8 Pa

Elongation 6.93e-4

Hardness - Vickers 2.77e10 Pa

Fatigue strength at 10^7 cycles 2.56e8 Pa

Fracture toughness 2.45e6 Pa.m^0.5

Melting point 3.21e3 °C

Maximum service temperature (Tmax) 862 °C

Minimum service temperature (Tmin) -273 °C

Thermal conductivity 21.2 W/m.°C

Specific heat capacity 556 J/kg.°C

Thermal expansion coefficient 6.99e-6 strains/°C

Latent heat of fusion 1.16e6 J/kg

Electrical resistivity 2.11e-6 ohms. m

Solidus temperature 2153 °C

Liquidus temperature 2113 °C

2.4.3.2 Application of titanium carbide

(a) Space applications

Ball bearings are the space tribology areas in which the coatings made an

achievement. Ball bearings by using TiC coatings are divided into two generations

that is different. The inner and outer steel races and combined with uncoated steel

balls become the first generation. While the used in TiC coating on the balls with

uncoated steel races become the second generation. (Boving and Hintermann, 1990).

(b) Application to advanced compressor design

32

SiC or Ti composites are good candidates for the manufacture of fully bladed

compressor rings (blings) because it capabilities of high temperature and the

mechanical properties is performed well. The composite is used as a ring to carry out

the very high hoop stresses raised in the disc and the titanium matrix enable to

achieve 600 ◦C of operating temperature (Carrere et al, 2003).

2.5 Production Tooling

Production tooling is one of the important elements in production whereby it is used to

keep the production going on well. Even the production tool was designed mostly in

simple, but without the tools the production will face problems. There are several types

of production tool; mostly used are jig, fixtures, vice, clamping and some other related

tools that being used during production. It is important to make sure all tools are in good

condition in order to reduce the impact of production.

2.6 Engineering Analysis Tools (FEA)

Historically, Finite Element Method was used in the late 1950’s and early 1960’s as a

tool to solve engineering problems commercially in industrial applications. In 1970’s

commercial programs started to emerge and at first FEM was restricted to costly

mainframe computers belonging to the aeronautics, automotive, defence and nuclear

industries and more companies started to use due to the usage have grown very rapidly.

Few examples of available commercial programs consist of ABAQUS, FLUENT,

Comsol Multiphysics, and ANSYS. However, ANSYS is a widely used commercial

general-purpose finite element analysis program (KTH, Nd).

On the other hand, the capabilities of ANSYS FLUENT software involves model flow,

turbulence, heat transfer, and reactions to be apply in industrial (Kremenestsky, 2011).

33

CHAPTER 3

METHODOLOGY

This chapter explains details on the development of the entire project via flow chart to

illustrate the whole project. This chapter acts as a guideline in order to accomplish the

project. This chapter involves the method of analysis, parameter to be determined and

some other related matters.

3.1 Flowchart of research activity

To complete the whole project, detailed planning is very important and it is intended to

facilitate the conduct of activities throughout the entire process. This is because, the

project needed to face the most crucial constraints such as time management, project

development, testing process, analysis process and selection process. The sequence of

the research activity has been provided as Figure 3.1 and was divided into five phases

and explained in more details in the next section.

34

Figure 3.1: Flow chart of research activities

No

Yes

Result?

Report writing

Design simulation using

ANSYS

The engineering

sketch & detailed

design

Sand casting

technique

Metal matrix

composite

Parameters of

production tools

Documentation

stage

Design of production tooling

Review design input

Literature review & Patent search Proposal

Design selection

Phase 1: Design Planning

Phase 2: Design proposal

Phase 4: Design Selection

Phase 5: Design Presentation

Phase 3: Design Simulation

PSM 1

PSM 2

End

Start

35

3.2 Phase 1: Design planning

3.2.1 Proposal

This is the first step in which the title of the project is selected and then the subject is

understood in detail to know the importance and purpose of the project. After finding out

its purpose, it is easy to know what the purpose of the project is. The scope of the project

will then determine the parameters to focus throughout the project.

3.2.2 Literature review and patent research

It is important to understand all the things related to the project to facilitate the process

throughout the project, and managed successfully. As example, Chapter 2 is a literature

review, in which each document or statements related to the project have been listed

based on previous research of the smoothing out of the project and help to achieve the

project objectives. Information obtained in each research is useful and can be used as a

reference during the implementation of the project. However, search patent search is one

of the resources that can help in the beginning of the process to design production tool

where it is as a reference to find out if the product is designed to have existed or not.

3.2.3 Review design input

It is important to refer to the resources that can provide guidance for the design of better

mould design, geometry, and patents and so on. Therefore, it is used as reference

material or input early in the design process.

36

3.3 Phase 2: Design proposal

3.3.1 Design of production tooling

Production tooling is composed of clamping, vice, jigs, fixtures and others. The V-block

jig was selected as the product throughout the implementation of this project, in which it

is applied in the drilling process and serves to facilitate the process implemented.

3.3.2 The engineering sketch and detailed design

Only one production tool design is available but it differentiates on the mould design.

Figure 3.2 shows the product 3D drawing using SolidWorks 2010.

Figure 3.2: 3D engineering drawing of production tool

Figure 3.3 shows the 2D engineering drawing of production tooling.

37

Figure 3.3: 2D engineering drawing of production tool

3.3.3 Sand casting technique

In this project, the sand casting is used due to it is easily to mixture material as described

in the early chapters. The mould design is based on the criteria and requirements of the

sand casting process in order to ensure that the resulting product will be good and

satisfactory.

38

3.3.4 Material

Metal matrix composite that consists of an aluminium silicon alloy or LM6 alloy

(A413.2) and titanium carbide (TiC (IV) Carbide ALDRICH -325 mesh. 98%) is used as

the main element of metal in the sand casting process. The materials are mixed together

to generate data for comparison in order to select of the best and most suitable mould

design based on analysis.

3.3.5 Parameters of production tools

Parameter setting is important to determine the best material choice and appropriate after

obtaining the results of the analysis performed. Therefore, the parameters to be

determined are, such as pressure, temperature rise or drop, mass flow rate, velocity,

volume, solidification time, density and cost.

3.3.6 Documentation stage

There are three concepts of mould design that is generated using SolidWork 2010 are

shown as Figure 3.4, Figure 3.5 and Figure 3.6.

39

Figure 3.4: Mould design of Concept 1


40


3.4 Phase 3: Design simulation

A design for sand mould is generated Using SolidWorks 2010. The models are analysed

by simulation via ANSYS Fluent software in order to determine the results based on the

parameter set.

3.4.1 Basic Data to Be Used As Input for ANSYS FLUENT

Before starting the simulation, the input data need to be gathered and calculated before

insert into ANSYS software to begin the simulation. Table 3.1 shows the value of

combination between LM6 alloy and titanium carbide with the percentage of 90 percent

and 10 percent.

41

Table 3.1: Material properties (CES Edupack 2010)

Properties

Material

LM6 alloy (90%)

+

Titanium carbide

(10%)

Sand silica (Si)

Density (kg/m^3) 2876 2320

Specific heat capacity (J/kg-k) 922.3 691

Thermal conductivity (W/m-k) 129.92 145

Solidus temperature 727.9 -

Liquidus temperature 739.1 -

Melting temperature 519.45 -

3.4.2 Setting of ANSYS CFX

ANSYS software is finite element analysis (FEA) software used to simulate the

characteristic of particles at a molecular level in a virtual space. The simulation result of

ANSYS is similar to the real experiment generated. ANSYS can help to carry out the

possible defects that may be a rise in the sand casting process.

3.4.2.1 Import Geometry

The first step to starting simulation of ANSYS FLUENT is to import the geometry to

simulate. Choose the types of analysis that will be conducted under Analysis System and

drag into Project Schematic as shown in Figure 3.7.

42

Figure 3.7: Import geometry into ANSYS software.

The drawn of 3D model needs to be saved as IGS file type in order to able the document

in ANSYS software. Right click on the Geometry and select Import Geometry in order

to import the 3D model into the ANSYS software. Next, double click on the Geometry

and Design Modeller will appear and click Generate button. Select the surface that acts

as inlet and right and right click to select Create Name Selection in order to rename the

surface as required name. It is the same step to another surface as shown in Figure 3.8.

43

Figure 3.8: Rename the surface as inlet and outlet.

3.4.2.2 Meshing

The next step is meshing the 3D model by double click on the Mesh and Mesh Setup

appeared. Select Mesh on Project tree and click generate Mesh icon. Set up the mesh

same as in Figure 3.9 and then click Update icon.

Figure 3.9: Mesh setting.

44

The results of meshing are shown in Figure 3.10.

Figure 3.10: Results of meshing

3.4.2.3 Setup

Next, click on the Setup icon and the FLUENT Launcher appeared. Just click on the OK

icon to proceed to the next step. Fluid Flow (FLUENT) appeared and go through the

problem setup first. Click on the General and select Transient under Solver and click the

Check icon under Mesh. Then, click Models and setup same as Figure 3.11.

Figure 3.11: Models setup

45

Go through the Materials under Problem Setup in order to set up the materials that had

been mentioned previously and input the value of the density, specific heat, thermal

conductivity, solidus temperature and liquidus temperature as shown in Figure 3.12.

Figure 3.12: Materials setup

Next, go through the Boundary Condition and click the Inlet under boundary Condition

and set the value same as Figure 3.13 and Figure 3.14.

46

Figure 3.13: Velocity Inlet setup

Figure 3.14: Velocity Inlet setup (temperature)

Next, go through the Boundary Condition and click the outlet under boundary Condition

and set the value same as Figure 3.15 and Figure 3.16.

47

Figure 3.15: Pressure Outlet setup (momentum)

Figure 3.16: Pressure Outlet setup (thermal)

Next, set up the wall-solid which the value same as the Figure 3.17.

48

Figure 3.17: Wall setup (thermal)

Then proceed with the Dynamic Mesh by setup same as Figure 3.18.

Figure 3.18: Dynamic Mesh setup

Next is selecting the Reference Values under Problem Setup and choose the inlet under

Compute From. Next, select the Solution Initialization under Solution and select input

under Compute From and click on the Initialize icon. In the Solution also, click Run

Calculation and click on the Check Case icon. Determine the value for Max

Iterations/Time Step and click Calculate icon and wait until the calculation complete.

After completing the calculation, go through the Graphics and Animations under Results

in order to view the results as shown under Graphics as shown in Figure 3.19.

49

Figure 3.19: Results

3.4.2.4 Results

The last but not least is to view the result of the simulation. The flow results are

observed by creating the streamline and the icon as shown in Figure 3.20.

Figure 3.20: Streamline icon

The streamline shows the flow of fluid throughout the mould cavity from the sprue until

the riser and exit. The details of the flow of time in streamline 1(s) can be viewed by

click on the Chart icon as shown in Figure 3.21.

Figure 3.21 Chart icon

50

3.4.3 Setting of Static Structural analysis

This analysis is continued from the ANSYS (FLUENT) by transfer the data to new in

order to generate Static Structural analysis through select on the Result of FLUENT by

right click and select the Transfer Data To New by choosing Static Structural same as

Figure 3.22.

Figure 3.22: Starting of Static Structural analysis

Double click on Model to refresh project. After seconds, view of Static-Structural

Mechanical appeared as shown in Figure 3.23 and need to be setup.

51

Figure 3.23: Static Structural-Mechanical

Under the Project tree, determine the solid which is to define the material used for

simulation as shown in Figure 3.24.

Figure 3.24: Select material

Under Static Structural, right click to select Force and input the value of force and the

direction on the surface to be analysed as same as Figure 3.25.

52

Figure 3.25: Force

Next, same as the step to select the force, select the thermal condition and identify the

surface as shown in Figure 3.26.

Figure 3.26: Thermal Condition

Right click the Solution and select another parameter includes total deformation (Figure

3.27), equivalent stress (Figure 3.28), thermal strain (Figure 3.29), a safety factor for all

bodies (Figure 3.30), and safety factor for two faces (Figure 3.31).

53

Figure 3.27: Total deformation

Figure 3.28: Equivalent stress

Figure 3.29: Thermal strain

Figure 3.30: Safety factor (all bodies)

54

Figure 3.31: Safety factor (2 faces)

3.5 Phase 4: Design selection

3.5.1 Design Selection

In the design selection stage, the three concepts of the mould design that had been

analysed was selected in terms of the performance regarding the static pressure, velocity

magnitude, internal energy, turbulent kinetic energy, wall shear stress and others related

parameter. The selection process was conducted through ranking concept in order to

determine the most suitable mould design concept to be implemented in future.

3.6 Phase 5: Design presentation

3.6.1 Report writing

In this stage, the whole thing is done during the execution of this project will wrote from

the beginning of the process upon completion of the project. The report consists of five

chapters which is an introduction, literature review, methodology, results and discussion

and last but not least is the conclusion and recommendation.

55

CHAPTER 4

RESULTS AND DISCUSSION

This chapter describes about the simulation analysis data and result for three design

concepts of mould by using ANSYS software in details. There are three conceptual

designs of mould whereby it different for position of sprue and riser that each of them

was analysed. Based on the result and data, the ranking method was used to determine

the best mould design that low weight as well as low waste in order to create the

production tool designs that environmentally friendly.

4.1 Concept Generation

Three designs were created and drawn in detail by using SolidWorks 2010 in which each

of the designs have different characteristics in terms of the sprue and riser position. The

main purpose of the design was to enable a smooth flow of molten in order to reduce and

prevent any casting defects.

56

4.1.1 Concept 1

This concept consists of a sprue and a riser in order to guide the molten flow

competently. The sprue and riser are located at the side of the cavity. 3D model of the

molten flow was generated using SolidWorks 2010 in order to be used for the purpose of

analysis in ANSYS software. Figure 4.1 shows the entire cavity of Concept 1.

Figure 4.1: Isometric view design Concept 1

4.1.2 Concept 2

This concept was different to the design of Concept 1 and Concept 3, whereby it was

different position of the sprue and the riser. The sprue and riser are located at the top of

the cavity. 3D model of the molten flow was generated using SolidWorks 2010 in order

to be used for the purpose of analysis in ANSYS software. Figure 4.2 shows the entire

cavity of Concept 2.

57


4.1.3 Concept 3

This concept was similar to Concept 1, whereby it was different position of sprue and

the riser. The sprue is located at the side of the cavity while the riser at the top of the

cavity. 3D model of the molten flow is generated using SolidWorks 2010 in order to be

used for the purpose of analysis in ANSYS software. Figure 4.3 shows the entire cavity

of Concept 3.


58

4.2 Design Selection

4.2.1 Simulation Results

All the following results are totally generated using ANSYS (FLUENT) software. The

steps of analysis data were clearly explained in Chapter 3. As the result of the analysis,

the values of minimum and maximum of total pressure, velocity magnitude, internal

energy, turbulent kinetic energy and wall shear stress was found. Besides that, the factor

of safety (FOS) was carried out by using Static Structural analysis. Further explanations

of the details analysis result were illustrated in this section.

4.2.1.1 Static Pressure

(a) Concept 1

Figure 4.4 shows the velocity vector coloured by the static pressure of Concept 1. The

values of minimum and maximum total pressure of gating system were -27599.36

Pascals and 25319.69 Pascals. The figure shows that at starting point of pouring the

molten, it was very high pressure occurs due to the changes of cross sectional area of the

sprue. Then, the pressure begins to decrease due to over large areas and at the riser

shows the pressure was at a lower rate.

59

Figure 4.4: Velocity vector coloured by static pressure of Concept 1

In Figure 4.5, the graph shows that the pressure was slightly higher at the sprue which

mean at the starting point of molten flow. The pressure dropped rapidly right after 0.04

seconds and gradually decreases as well as the time progress until the pouring ends.

Figure 4.5: Graph static pressure of Concept 1

60

(b) Concept 2


values of minimum and maximum total pressure of gating system were -16542.2 Pascal

and 19884 Pascals. The figure shows at the starting point of pouring molten, it was very

high pressure due to the location of sprue and cross sectional area decrease. While the

metal entering the cavity, it shows some decreasing of pressure due to the spread area of

molten flow was increased. However, the pressure still remains at high whenever reach

to the riser and exit.

Figure 4.6: Velocity vector coloured by static pressure Concept 2



seconds and gradually decreases to the pressure at 7500 Pa after 0.02 seconds then arise

to pressure at 9900 Pa after 0.02 seconds. The pressure then decreases to 9500 Pa as well

as the time progress until the pouring ends.

61


(c) Concept 3


values of minimum and maximum total pressure of gating system were -28851.9 Pascals

and 21166.92 Pascals. The figure shows that at starting point of pouring the molten, it

was very high pressure occurs due to the changes of cross sectional area of the sprue.

Then, pressure begins to decrease due to over large areas and at the riser shows the

pressure was at a lower rate.

62

Figure 4.8: Velocity vector coloured by static pressure of Concept 3



seconds at 7000 Pa. Then rise to 10000 Pa in 0.02 seconds and gradually decreases to -

5000 Pa as well as the time progress until the pouring ends.


63

4.2.1.1.1 Comparison between concept

Based on the Figure 4.10, the graph shows that the highest static pressure was Concept 1

while the lowest was Concept 2. Basically, the lower static pressure was the better due to

fewer defects occur in the process of casting. As the result, Concept 2 was chosen as the

best concept in terms of the pressure.

Figure 4.10: Graph comparison of static pressure and concept

4.2.1.2 Velocity

(a) Concept 1

Figure 4.11 shows the velocity vector coloured by the velocity magnitude of Concept 1.

The values of minimum and maximum velocity magnitude were 0 m/s and 5.53 m/s.

From the figure, it shows that the velocity at starting point of molten flow was low.

However, the velocity was a bit higher in the fillet area due to the inappropriate runner

design and the dimension of sprue was smaller. Then, molten fills the cavity with low

velocity and bit increased during through riser due runners was designed in small

dimension.

0

5000

10000

15000

20000

25000

30000

0 1 2 3 4

Sta

tic

Pre

ssu

re (

Pa

)

Concept

Static Pressure vs Concept

64

Figure 4.11: Velocity vector coloured by velocity magnitude of Concept 1

In Figure 4.12, the graph shows velocity was increased from 0.5 m/s to 2.9 m/s in 0.04

seconds and decreased to 0.4 m/s in 0.12 seconds. However, the velocity then slightly

increased to 3.2 m/s in 0.03 seconds and decreased as well as the time progress until the

pouring ends. The diameter of sprue design affected the velocity of molten flow which it

was important to ensure the molten flow consistently before the temperature dropped. In

addition, if the flow of molten was not consistently or too low, it will cause the molten

flow slowly and solidify before fully fill in the cavity.

65

Figure 4.12: Graph velocity magnitude of Concept 1

(b) Concept 2



From the figure, it shows that the velocity was moderate at the starting point of pouring

molten due to the location of sprue that place on the top of the cavity. When the molten

entering into the cavity, the velocity was slightly decreased and spread to fill the entire

cavity. The velocity suddenly increased at the ending point of molten flow due to the

dimension of the riser was reduced.

66


In Figure 4.14, the graph shows that the velocity was increased from 0.5 m/s to 2.3 m/s

in 0.03 seconds and decreased as well as the time progress until the pouring ends. The

diameter of sprue design affected the velocity of molten flow which it was important to

ensure the molten flow consistently before the temperature dropped. However, the

position of sprue that was located on the top of the mould cavity affect the velocity of

molten flow. In addition, if the flow of molten was not consistently or too low, it will

cause the molten flow slowly and solidify before fully fill in the cavity.

67


(c) Concept 3



From the figure, it shows that the velocity at starting point of molten flow was low.

However, the velocity was a bit higher in the fillet area due to the inappropriate runner

design and the dimension of sprue was smaller. Then, molten fills the cavity with low

velocity and bit increased during through riser due to the runners was located on the top

of the cavity.

68


In Figure 4.16, the graph shows that the velocity has slightly increased from 0.5 m/s to

2.9 m/s in 0.05 seconds and decreased to 0.4 m/s in 0.08 seconds. However, the velocity

starts to increase from 0.5 m/s to 2.4 m/s in 0.03 seconds and then decrease again as well

as the time progress until the pouring ends.



69

Based on the Figure 4.17, the graph shows that the highest velocity magnitude was

Concept 1 and the lowest was Concept 2. According to Campbell (2004), filling of the

mould can be carried out down, along, or up but along and up modes totally fulfil the

non-surface turbulence condition. When the molten above the critical velocity, there was

the danger of surface entrainment leading to defect create meanwhile below the critical

velocity the melt was safe from entrainment problem. The maximum velocity condition

effectively forbids top gating of castings because liquid aluminium reaches its critical

velocity about 0.5 m/s after falling only 12.5 mm under gravity. Castings that never

exceeded the critical velocity were consistently strong, with high fatigue resistance, and

leak tight. He also stated that the experiment on casting aluminium have demonstrated

that the strength of castings may reduce by as much as 90 percent or more if the critical

velocity exceeded. As the result, Concept 2 was chosen as the best concept in terms of

the velocity magnitude.

Figure 4.17: Graph comparison of velocity magnitude and concept

4.2.1.3 Internal energy

(a) Concept 1

0

1

2

3

4

5

6

0 1 2 3 4

Vel

oci

ty m

ag

nit

ud

e (m

/s)

Concept

Velocity Magnitude vs Concept

70

Figure 4.18 shows the velocity vector coloured by the internal energy of Concept 1. The

values of minimum and maximum internal energy of gating system were 3280 J/kg and

503083.50 J/kg. From the figure, it shows that the internal energy at the starting point of

molten flow was high. However, it was becoming lower when entering to fill the molten

to entire cavity.

Figure 4.18: Velocity vector coloured by the internal energy of Concept 1

In Figure 4.19, the graph shows that the internal energy was at 1e-02 J/kg and decreased

to 1e-4 J/kg as the completion of 250 iterations.

71

Figure 4.19: Graph internal energy of Concept 1

(b) Concept 2


values of minimum and maximum internal energy of gating system were 3280 J/kg and

503083.50 J/kg. From the figure, it shows that the internal energy at the starting point of

molten flow was high in order to enter the cavity. However, it was becoming lower after

entering to fill the molten to entire cavity. It also shows that the internal energy at the

exit to the riser was increased but still considered as low.

72


In Figure 4.21, the graph shows that the internal energy was at 1e-02 J/kg and slowly

decreased to 1e-3 J/kg as the completion of 250 iterations.


(c) Concept 3


values of minimum and maximum internal energy of gating system were 3635.23 J/kg

73

and 502949 J/kg. From the figure, it shows that the internal energy at the starting point

of molten flow was high in order to enter the cavity. However, it was becoming lower

after entering to fill the molten to entire cavity and still remain until exit to the riser.


In Figure 4.23, the graph shows that the internal energy was at 1e-02 J/kg and slowly

decreased to 1e-3 J/kg as the completion of 250 iterations.


74

4.2.2.3.1 Comparison between concepts

Based on the Figure 4.24, the graph shows that the highest internal energy was Concept

1 and the lowest was Concept 2. Lower internal energy was the better and it means that

fewer energy that came out of the body. In accordance with the first law of

thermodynamics, when a system undergoes a change of state as a result of a process in

which only work was involved, the work was equal to the change in internal energy. As

the result, Concept 2 was chosen as the best in terms the performance of internal energy.

Figure 4.24: Graph comparison of internal energy and concept

4.2.1.4 Turbulence kinetic energy

(a) Concept 1

Figure 4.25 shows the velocity vector coloured by the turbulence kinetic energy of

Concept 1. The values of minimum and maximum turbulence kinetic energy of gating

system were 3.7e-08 m2/s

2 and 0.796 m

2/s

2. From the figure, it shows that the turbulence

kinetic energy at starting point of pouring molten into sprue was very low but increase a

bit at the runner area due to the changes of cross sectional area. The molten spread to

502400

502500

502600

502700

502800

502900

503000

503100

503200

0 1 2 3 4

Inte

rna

l en

erg

y (

J/k

g)

Concept

Internal Energy vs Concept

75

entire cavity with lower kinetic energy and the value of the kinetic energy increase at the

exit point due to the diameter of the riser was in small dimension.

Figure 4.25: Velocity vector coloured by the turbulence kinetic energy of Concept 1

In Figure 4.26, the graph shows that the turbulence kinetic energy does occur at the

beginning of pouring the molten due to the changes of cross sectional area from large to

small but it was considered as normal condition. However, the turbulence was at its peak

at 0.19 seconds which is 0.38 m2/s

2. The rest of molten flow was considered as smooth

flow.

Figure 4.26: Graph turbulence kinetic energy of Concept 1

76

(b) Concept 2




2 and 0.69 m

2/s

2. From the figure, it shows that the turbulence

kinetic energy at starting point of pouring molten into sprue was very low but increase a

bit at the entrance into mould cavity. The molten spread to entire cavity with lower

kinetic energy until molten flow at the exit point near to riser located.


In Figure 4.28, the graph shows that the turbulence kinetic energy does occur and its

peak at 0.065 seconds which is 0.14 m2/s

2. Even the turbulence occurs during pouring

molten into the mould cavity, the amount was still minimal and consider as smooth flow

of molten before solidification begins.

77


(c) Concept 3




2 and 1.031 m

2/s

2. From the figure, it shows that the

turbulence kinetic energy at starting point of pouring molten into sprue was very low but

increase a bit at the runner area due to the changes of cross sectional area. The molten

spread to entire cavity with lower kinetic energy and the value of the kinetic energy

increase at the exit point due to the diameter of the riser was in small dimension.

78


In Figure 4.30, the graph shows that the turbulence kinetic energy does occur and its

peak at 0.138 seconds which is 0.44 m2/s

2. Even the turbulence occurs during the molten

fill into the entire mould cavity, the amount was still minimal and consider as smooth

flow of molten before solidification begins.


79

4.1.2.4.1 Comparison between concepts

Based on the Figure 4.31, the graph show that the highest turbulent kinetic energy was

Concept 3 and the lowest was Concept 2. Lower kinetic energy was the better and it

means that fewer energy that's lost from the body. As the result, Concept 2 was chosen

as the best in terms the performance of kinetic energy.

Figure 4.31: Graph comparison of turbulence kinetic energy and concept

4.2.1.5 Wall shear stress

(a) Concept 1

Figure 4.32 shows the velocity vector coloured by the wall shear of Concept 1. The

values of minimum and maximum wall shear stress of gating system were 0 Pa and

91.33 Pa. From the figure, it shows that the wall shear stress at starting point of pouring

molten into sprue was very low but it was a bit high in the fillet area of the runner. It was

remained low condition on wall shear stress during the molten spread to entire cavity.

But increase a bit in the fillet area of the riser.

0

0.2

0.4

0.6

0.8

1

1.2

0 1 2 3 4

Tu

rbu

len

t k

inet

ic e

ner

gy

(m

2/s

2)

Concept

Turbulent Kinetic Energy vs Concept

80

Figure 4.32: Velocity vector coloured by wall shear of Concept 1

(b) Concept 2




molten into sprue was very low while entering the cavity and it was remain the condition

during the molten spread to entire cavity and exit through the riser.


81

(c) Concept 3




molten into sprue was very low but it was a bit high in the fillet area of the runner. It was

remained low condition on wall shear stress during the molten spread to entire cavity.

But increase a bit in the fillet area of the riser.



Based on the Figure 4.35, the graph show that the high wall shear stress was Concept 3

and the lowest was Concept 2. Lower wall shear was the better and it means that fewer

collisions between the particles while moving in order to filling the entire space of the

cavity. As the result, Concept 2 was chosen as the best in terms the performance of wall

shear.

82

Figure 4.35: Graph comparison of wall shear and concept

4.3 Static Structural Analysis

All the results of the static structural analysis were generated from the ANSYS software

whereby the analysis was a continuation of the ANSYS (FLUENT). The best concept

design that had been selected for further analyzed was Concept 2. The information from

ANSYS (FLUENT) analysis was linked to the static structural analysis in order to

proceed for the new simulation. The results of the static structural analysis were

explained further details in the next section. In the analysis, the force applied to the

surface area was 500 N as shown in Figure 4.36.

0

20

40

60

80

100

0 1 2 3 4

Wal

l sh

ear

(P

a)

Concept

Wall Shear vs Concept

83

Figure 4.36: Applied force 500N

The thermal condition for this analysis was set to 22 °C as shown in Figure 4.37. It is

because the V-block jig was applied as functional to clamp the workpiece in the drilling

process in order to make holes or others required operation. There were two surfaces of

V-block jig that was the most critical area.

Figure 4.37: Applied thermal condition 22 °C

84

4.3.1 Total deformation

Figure 4.38 shows the results of total deformation of static structural analysis. The

values of minimum and maximum of total deformation were 157.61 m and 176.05 m.

This means that the pattern can deform much.

Figure 4.38: Total deformation

4.3.2 Equivalent (von-Mises) stress

Figure 4.39 shows the results of equivalent (von-mises) stress of static structural

analysis. The values of minimum and maximum of equivalent (von-mises) stress were

73885 Pa and 1.2387e6 Pa.

85

Figure 4.39: Equivalent (von-mises) stress

4.3.3 Thermal strain

Figure 4.40 shows the results of thermal strain of static structural analysis. The values of

minimum and maximum of thermal strain were 0 m/m and 0 m/m.

Figure 4.40: Thermal strain

86

4.3.4 Factor of safety (FOS)

(a) FOS of two faces

Figure 4.41 shows the results of safety factor for two faces selected. The values of

minimum and maximum of safety factor was 15. It means that the design was good in

terms of the factor of safety was higher than 1.

Figure 4.41: FOS for two faces

(b) FOS of all body

Figure 4.42 shows the results of safety factor for all bodies selected. The values of

minimum and maximum of safety factor were 15 and 4.2463. It means that the design

was good in terms of the factor of safety was higher than 1.

87

Figure 4.42: FOS for all bodies

4.4 Summary of Results

As a conclusion by comparing all the three concepts and the required parameter, the

ranking stage determined that the best concept to be selected was Concept 2 based on

Table 4.1. The Concept 2 shows the best performance among two other concepts which

were lower in static pressure, lower in velocity magnitude, lower in internal energy,

lower in turbulent kinetic energy and lower inside wall shear stress.

Table 4.1: Ranking for three concepts

Parameter Concept 1 Concept 2 Concept 3

Static pressure 3 1 2

Velocity magnitude 3 1 2

Internal energy 3 1 2

Turbulent kinetic energy 2 1 3

88

Wall shear stress 2 1 3

Total 3 1 2

The value of 1 refers to the best design concept, value of 2 refers to the moderate design

concept and the value of 3 refers to the weakest design concept of mould. Therefore, the

results from tabulated shows that the best concept design of mould was belong to

Concept 2.

After completing the ranking stage, the selected Concept 2 was further analysed through

static structural analysis whereby the most critical faces or area of V-block jig was

applied force in order to determine the factor of safety (FOS). Based on the simulation

results shows that the factor of safety for all bodies and surface of the V-block jig was

valid due to the value was higher than 1. The summary of factor of safety (FOS) was

tabulated in Table 4.2.

Table 4.2: Summary of FOS

Factor of Safety (FOS)

Results

Minimum Maximum

All bodies 4.2463 15

2 faces 15 15

89

CHAPTER 5

CONCLUSION AND FUTURE WORK

This chapter briefly explains about the summarization of the whole project based on the

results and objectives of the study. Therefore, the suggestion and recommendation are

given in order to improve the result in the future study.

5.1 Conclusion

As a conclusion, all of the objectives for this project successfully achieved. A new

mould design concept of production tooling has been created using casting method. The

results from the analysis shows that the combination 90 % of LM6 Alloy and 10%

Titanium Carbide (TiC) produces a strong and suitable molten and able to flow smoothly

throughout the mould cavity. The fluid flow of three concept design of mould in sand

casting was analysed via ANSYS FLUENT software based on the parameter of pressure,

velocity, temperature, turbulence and wall shear. The factor of safety had been carried

out and shows the results that the pattern of V-block jig was safe to be implemented in

designing of production tooling. As a result, the casted of 90 % of LM6 Alloy and 10%

Titanium Carbide (TiC) was potential to produce in designing of production tooling.

90

Recommendation

As a future recommendation for the next stage of this project, the project should be

conducted in the real experiment of sand casting process in order to determine whether

there was any defects occur using the designed mould dimensions that consist of LM6

alloy and titanium carbide materials. To obtain accurate and better results, the casting

process should be performed as much as possible in order to reduce human error and

unexpected error that may affect the result of casting.

91

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APPENDIX A

APPENDIX B

APPENDIX C

APPENDIX D

APPENDIX E

APPENDIX F

Documents

UNIVERSITI TEKNIKAL MALAYSIA MELAKA - eprints.utem.edu.myeprints.utem.edu.my/11968/2/Design_And_Analysis_Of... · 2.1 Hierarchical classification of various casting processes 7 2.2