Engineering Design And Construction Of Stir Casting Shop For Manufacturing Processes

ABSTRACT

Non-homogeneous particle distribution is one of the greatest problems in casting of metal matrix composites (MMC’s), because of ceramic materials have different density, melting point and boiling point. But other light materials like Aluminium, copper and magnesium etc, have less density of melting point and boiling point, so ceramic particle mixing is very difficult to light materials.

This project deals with design of the solid model components of stirrer assembly stand, stirrer rod, stirrer blade, base stand and are designed with require dimensions to design and fabricate the stir casting machine.

In this machine the stirrer blade is coupled with the stirrer shaft and motor is kept separately whereas the power is transmitted to the shaft with the help of groove pulleys. The stirrer rod designed by variation of speed (400 – 600 rpm) for mixing purpose. We can set any constant rpm or any variation rpm at any time. After mixed molten metal can be transfer into the mould with constant temperature. From this cast part improve all the mechanical properties without casting defects.

TABLE OF CONTENTS

COVER PAGE

TITLE PAGE

APPROVAL PAGE

DEDICATION

ACKNOWELDGEMENT

ABSTRACT

CHAPTER ONE

INTRODUCTION

1.1      BACKGROUND OF THE STUDY

• PROBLEM STATEMENT
• AIM AND OBJECTIVE OF THE STUDY
• SIGNIFICANCE OF THE STUDY
• SCOPE OF THE STUDY
• PROJECT MOTIVATION

CHAPTER TWO

LITERATURE REVIEW

• REVIEW OF THE STUDY
• OVERVIEW OF STIR CASTING
• MELTING OF MATRIX MATERIAL
• MECHANICAL STIRRING
• EFFECT AND OPTIMIZATION OF STIRRING PROCESS PARAMETERS
• PROCESS PARAMETERS OF STIR CASTING
• HISTORICAL BACKGROUND OF METAL CASTING
• REVIEW OF RELATED STUDIES

CHAPTER THREE

3.0      METHODOLOGY

3.1      MATERIAL SELECTION FOR STIR CASTING SETUP

3.2      COMPONENTS AND MATERIALS

CHAPTER FOUR

• MECHANISM AND FABRICATION
• FABRICATION
• RESULT AND DISCUSSION
• ASSEMBLY OF COMPONENTS
• CALCULATION
• COST ESTIMATION
• COMPARISION
• RESULT
• APPLICATION

CHAPTER FIVE

• CONCLUSION

REFERENCES

CHAPTER ONE

1.0                                                 INTRODUCTION

1.1                                   BACKGROUND OF THE STUDY

In a stir casting process, the reinforcing phases are distributed into molten matrix by mechanical stirring. Stir casting of metal matrix composites was initiated in 1968, when S. Ray introduced alumina particles into aluminium melt by stirring molten aluminium alloys containing the ceramic powders. Mechanical stirring in the furnace is a key element of this process. The resultant molten alloy, with ceramic particles, can then be used for die casting, permanent mould casting, or sand casting.

Stir casting is suitable for manufacturing composites with up to 30% volume fractions of reinforcement. The cast composites are sometimes further extruded to reduce porosity, refine the microstructure, and homogenize the distribution of the reinforcement. A major concern associated with the stir casting process is the segregation of reinforcing particles which is caused by the surfacing or settling of the reinforcement particles during the melting and casting processes.

An interesting recent development in stir casting is a two-step mixing process. In this process, the matrix material is heated to above its liquids temperature so that the metal is totally melted. The melt is then cooled down to a temperature between the liquids and solidus points and kept in a semi-solid state.

For making the frame we have used nut and bolt join so that we can easily change the dimensions as per the requirement so we did drilling as per the dimension.

After completion of that we did machine work to make the components ready for assembly, mainly we used drilling process to make holes for frame, we used lathe machine to do facing, turning and boring, finally with the help of grinding machine we completed our components ready for assembling.

1.2                                          PROBLEM DEFINITION

Generally, stir casting process plays major role in case of Metal Matrix Composites (MMC) for attaining better mechanical properties. In this process the stir blade with rod coupled with motor is used to mix the reinforcement with the molten metals.

In small scale industries, where the capital investment is not much they cannot afford such high-priced machine. So, the aim is to find a solution to the above problem by designing and fabricating a stir casting machine that can be used with crucible furnace to melt and mix the metal matrix composites at variable speed and of low production cost. Hence the initial investment will also be hugely reduced (8000rs approx.)

1.3                             AIM AND OBJECTIVE OF THE STUDY

The main aim of this work is to build a stir casting setup for manufacturing process. The objectives of the project are:

1. To setup a stir casting shop using available materials
2. To study the process of heating and melting aluminum metal.

• To study the application of Aluminium Matrix Composites

1. To achieve uniform distribution of the reinforcement material
2. To minimize porosity in the cast metal matrix composite

1.4                                        SCOPE OF THE PROJECT

The scope of the study is to develop a stir casting is one of the novel methods to produce metal matrix composites with more uniform distribution of matrix and reinforcement constituents. This approach involves mechanical mixing of the reinforcement particulates/particles into a molten metal bath. A crucible is heated to malt aluminum metal, with a motor and blades is placed in the crucible that helps to get uniform molten metal. The reinforcement is poured into the crucible above the melt surface and at a controlled rate, to ensure a smooth and continuous feed. As the blades rotate at moderate speeds, it generates a uniform mixing of the reinforcement particles into the melts to produce homogenous composites.

1.5                                    SIGNIFCANCE OF THE STUDY

Carrying out this research will help the researcher to understand how stir casting is one of the most universally used approach to manufacture particle reinforced composites and among all the fabrication techniques considered, stir casting stands out as the most economical method.

It will help the reader to learn how to setup a stir casting shop using locally available materials.

1.6                                          PROJECT MOTIVATION

The cost of buying the imported stir casting machine is to high, this lead to the locally setup of the device. Since locally made stir casting being economical, simple, time saving and it is having more significance than other casting process. With the help of stir casting process it is proved to manufacture castings in large quantities which is not quite possible in other casting process which are used to produce MMCs. However, advantages discussed above were points that motivate the carrying out of this research work.