comparison of sand casting surface roughness and...

COMPARISON OF SAND CASTING SURFACE ROUGHNESS

AND DIMENSION ACCURACY BETWEEN ALUMINIUM

SILICON CARBIDE AND TIN SILICON CARBIDE

ABD HALEM BIN ABD RAZAK

B050810290

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

2011


COMPARISON OF SAND CASTING SURFACE ROUGHNESS AND

DIMENSION ACCURACY BETWEEN ALUMINIUM SILICON

CARBIDE AND TIN SILICON CARBIDE

This report submitted in accordance with requirements of the Universiti Teknikal

Malaysia Melaka (UTeM) for the Bachelor of Manufacturing Engineering

(Manufacturing Process)

by

ABD HALEM BIN ABD RAZAK

B050810290

FACULTY OF MANUFACTURING ENGINEERING

2011


BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: Comparison of Sand Casting Surface Roughness and Dimension Accuracy

between Aluminium Silicon Carbide and Tin Silicon Carbide

SESI PENGAJIAN: 2010/2011 Semester 2

Saya ABD HALEM BIN ABD RAZAK

mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal

Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis.

2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk

tujuan pengajian sahaja dengan izin penulis.

3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan pertukaran

antara institusi pengajian tinggi.

4. **Sila tandakan (√)

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam

AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan

oleh organisasi/badan di mana penyelidikan dijalankan)

Alamat Tetap:

NO 26, Jalan Desa Molek 12,

Taman Desa Molek, Air Molek,

75460, Melaka.

Tarikh: 20 May 2011

Disahkan oleh:

PENYELIA PSM Tarikh: 20 May 2011

DECLARATION

I hereby, declared this report entitled “Comparison of Sand Casting Surface

Roughness and Dimension Accuracy between Aluminum Silicon Carbide and Tin

Silicon Carbide” is the results of my own research except as cited in references.

Signature : ……………………………....

Author’s Name : Abd Halem Bin Abd Razak

Date : 20 May 2011

APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM as

a partial fulfillment of the requirements for the degree of Bachelor of

Manufacturing Engineering (Manufacturing Process). The members of the

supervisory committee are as follow:

………………………………

Principle Supervisor

………………………………

Co- Supervisor

i

ABSTRAK

Tuangan pasir adalah proses tuangan logam lebur yang akan dituang kedalam acuan.

Dalam kajian ini, mengkaji antara aluminium silicon carbide dengan tin silicon

carbide untuk mengetahui kekasaran permukaan dan ketepatan dimensi (mm).

Objektif utama perlaksanaan kajian ini adalah untuk mengkaji kekasaran permukaan

dan ketepatan dimensi (mm) manakah yang baik melalui proses tuangan pasir untuk

alat pengeluaran. Dalam kajian ini, bahan utama yang digunakan ialah aluminium

LM6 dan tin sebagai bahan utama dan ‘silicon carbide’ sebagai bahan yang

digunakan untuk penetulang. Sebelum melakukan proses tuangan pasir, bahan ini

akan di komposisikan antara aluminium dan tin dengan ‘silicon carbide’ mengikut

pembolehubah yang ditetapkan. Daripada analisis antara aluminium dan tin akan

mengkaji antara bahan yang berlainan akan mempengaruhi prestasi produk akhir

dalam kontek ketepatan dimensi (mm) dan kekasaran permukaan.

ii

ABSTRACT

Casting process basically involves pouring molten metal into a mould cavity. In this

study, aluminum and tin with reinforcement with silicon carbide to determine

affected surface roughness and dimensional accuracy (mm). The main objective of

the implementation of this study was to investigate the different material aluminium

and tin reinforcement with silicon carbide on dimensional accuracy and surface

roughness using sand casting for manufacturing equipment. In this study, the main

material used is aluminum LM6 and tin as the main material and the silicon carbide

as the material used to reinforcement. Before the process of sand casting, this

material will be composition between aluminum and tin with the silicon carbide.

From the analysis of aluminum and tin with material composition will be affect the

performance of the final product in the context of dimensional accuracy (mm) and

surface roughness.

iii

ACKNOWLEDGEMENT

Alhamdulillah and thank to Allah S.W.T. for giving me strength and ability to

accomplish this project research successfully. I would like to take the utmost

opportunity to express my sincere and gratitude to my supervisor, Prof. Dr. Mohd

Razali Bin Muhamad and core supervisor, Mr Taufik who is always giving me

supports and guidance throughout the year in completing this ‘Projek Sarjana Muda’.

Besides that, thanks a lot to all lecturers and staffs of Faculty of Manufacturing

Engineering.

Finally, to all my fellow friends who involves direct or indirectly that always stand

strong beside me in giving opinions and supports throughout our relationship, I really

thankful and appreciate it.

iv

DEDICATION

This thesis is dedicated to my parents Abd Razak Bin Md Yatim and Awa Bte Che

Mat who introduced me to the joy of reading from birth, enabling such a study to

take place today.

v

TABLE OF CONTENT

Abstrak i

Abstract ii

Acknowledgement iii

Dedication iv

Table of Content v

List of Tables ix

List of Figures xi

List of Abbreviations xiv

1. INTRODUCTION 1

1.1 Background 1

1.2 Problem Statement 2

1.3 Objective 3

1.4 Scope of the Project 3

2. LITERATURE REVIEW 4

2.1 Casting 4

2.1.1 Introduction 4

2.1.2 Sand Casting 5

vi

2.1.3 The Sand Casting Process 7

2.1.4 Mould Design 14

2.2 Aluminium 15

2.2.1 Introduction 15

2.2.2 Aluminium Silicon Carbide 16

2.2.3 Aluminium Casting 17

2.3 Tin Properties 17

2.4 Metal Matrix Composite 19

2.5. Reinforcement 20

2.6 Surface Roughness 21

2.7 Dimension Accuracy 22

3. METHODOLOGY 28

3.1 Introduction 28

3.2 Flow chart methodology process 29

3.3 Mechanical Drawing Part 30

3.3.1 SolidWorks 30

3.3.2 Drawing Part 30

3.4 Fused Deposition Modelling (FDM) 31

3.4.1 Machine Specification 32

3.4.2 Working Procedure Fused Deposition Modelling (FDM) 33

vii

3.5 Material Preparation 34

3.6 Sand casting Procedure 35

3.6.1 Mould Design 36

3.6.2 Flow Chart of Step in Sand Casting 37

3.6.3 Step Casting Process 38

3.7 Measurement Equipment 42

3.7.1 Surface Roughness Measurement 42

3.7.2 Basic Specification 43

3.7.3 Dimension Accuracy 43

3.7.4 Coordinate Measuring machine (CMM) 45

3.7.5 Coordinate Measuring machine (CMM) Specification 45

3.7.6 Working Procedure Coordinate Measurement Machine (CMM) 46

4. RESULT 48

4.1 Introduction 48

4.2 Surface Roughness Result 48

4.2.1 Surface Roughness Analysis 57

4.3 Dimension Accuracy 59

4.31 Dimension Accuracy Analysis 62

5. DISCUSSION 63

5.1 Introduction 63

viii

5.2 Sand Properties 63

5.3 Pattern Design 64

5.4 Effect Material Composition 65

5.5 Effect Pouring 65

5.6 Effect Gating Systems 66

5.7 Impact Toughness Test 67

6. CONCLUSION AND FUTURE WORKS 71

6.1 Introduction 71

6.2 Conclusion of Research 71

6.3 Future Works 72

REFERENCES 73

APPENDICES

A. Gantt Chart PSM

B APPENDIX B

ix

LIST OF TABLES

2.1 Melting points of some metals 15

2.2 The characteristics of aluminium silicon Carbide 16

2.3 The characteristics of tin 18

2.4 Summarization of the research 24

3.1 400mc specifications (Stratasys, FDM 400mc, system documentation) 32

3.2 Material composition with silicon carbide percentage 34

3.3 Specification of Portable Surface Roughness Tester 43

SJ-301 for X-axis (drive unit)

3.4 Specification of Portable Surface Roughness Tester, SJ-301 for detector 44

3.5 Wenzel LH54 specifications 45

4.1 Aluminium Silicon Carbide result surface roughness 49

4.2 Tin Silicon Carbide result surface roughness 53

4.3 Summarization research on the surface roughness analysis in sand casting 58

4.4 The result aluminium silicon carbide data dimension 60

4.5 The result tin silicon carbide data dimension 61

4.6 Summarization research on the dimension accuracy analysis in 62

sand casting

x

5.1 The result Aluminium silicon carbide Toughness testing 69

5.2 The result Tin silicon carbide Toughness testing 69

xi

LIST OF FIGURES

2.1 Pouring molten metal into mould 5

2.2 Two moulds ready for pouring and one left open to show care 8

2.3 A mould, pattern and core box for simple casting 10

2.4 Procedure for making mould 10

2.5 Schematic illustration of sequence of operation for sand casting 11

2.6 Schematic illustration of typical riser-gated systems 13

2.7 Schematic illustration of sand mould, showing various features 14

3.1 Experiment methodology 29

3.2 Isometric projection drawing 30

3.3 3rd

view projection drawing 31

3.4 FDM 400mc machine 32

3.5 Product using FDM machine 33

3.6 Silicon Carbide weighed with a weighing scale 34

3.7 The bell casting basic training equipment. 35

3.8 Methodology of step sand casting process 37

3.9 Pattern using FDM machine 38

3.10 Core plate 38

3.11 Insert (CO2) into drag pattern plate 39

xii

3.12 Cope after ramming with sand and removing pattern, spure, and risers 39

3.13 Drag plate pattern 39

3.14 Process drag removing pattern 40

3.15 Drag after removing pattern 40

3.16 Core and drag will with plaid pattern 40

3.17 Core and drag assemble 41

3.18 The molten metal is then poured into the mould 41

3.19 The part is allowed to sit and cool 42

3.20 The part is removed from mould 42

3.21 Portable Surface Roughness Tester, Mitutoyo SJ-301 43

3.22 Coordinate Measuring Machine (CMM) Wenzel LH54 45

4.1 Measurement surface roughness using Portable Surface Roughness 49

Tester, Mitutoyo SJ-301

4.2 Result testing 1 aluminium silicon carbide surface roughness 50





4.7 Result testing 1 tin silicon carbide surface roughness 54



xiii



4.12 Measurement dimension accuracy using Coordinate Measure 59

Machine (CMM)

5.1 Effect the sand mould in core and drag 64

5.2 Sample Impact toughness testing 67

5.3 Pendulum Impact tester machine 68

xiv

LIST OF ABBREVIATIONS

ABS - Acrylonitrile Butadience Styrene

Al - Aluminum

AlSic - Aluminum Silicon Carbide

BOM - Bil of Material

CMM - Coordinate Measurement Machine

CO2 - Carbon Oxide

FDM - Fused Deposition Machine

LCD - Liquid Crystal Display

Mm - Millimeter

MMC - Metal Matrix Composite

m/s - meter per second

Pa - Pascal

Ra - Roughness Average

RSM - Root Mean Square

SiC - Silicon Carbide

SiO2 - Silicon Oxide

TinSic - Tin Silicon Carbide

1

CHAPTER 1

INTRODUCTION

1.1 Background

In this study, production tool is produced by using sand casting process. The

important element in this study is how to build the accurate dimension accuracy

production tool using and surface roughness by sand casting process. The conceptual

model of part is created by using software SolidWorks for produce pattern.

Typically, these processes involve the design of the production tool part using Solid

Works because easy for the designer to interpreted their design and not only fitted

with 2Dimensional axis only. Using SolidWorks, the design can be drawn in 3-

dimensional (3D) and also drawn in full scale measurement.

The master pattern from SolidWorks and then transferred to Fused Deposition

Machine (FDM) machine rapid prototype to create a final part. The pattern is made

up from ABS material using FDM machine. The next process is sand casting process

and is done by melt the actual master pattern in carbon dioxide (CO2) sand mold.

The quality characteristic such as dimensional accuracy will be analyzed using

Coordinate Measure Machine (CMM) and portable surface roughness tester.

2

Apart from that, the reason to conduct this study is to compare the dimension

accuracy and surface roughness between aluminum and tin material composition

produced by sand casting. Several literature reviews, generally from published

journal, are undertaken into this study to identify the significant effect of dimensional

accuracy and surface roughness of produced parts. Casting process is the basically

involves pouring molten metal into a mould cavity where upon solidification its takes

the shape of cavity. A wide variety of the product can be cast. This process is capable

of producing intricate shape in one piece including those with internal cavities. The

fundamental is essential for the production of good quality and economical casting

and for establishing proper technique for mould design casting practice.

Solidification and cooling of metals in the mould are effected by several factors

including the metallurgical and thermal properties of the metal. The type of mould

also has important influence because it affects the rate of cooling of the metal in the

mould (Kalpakjian and Schmid, 2006). The reinforced with silicon carbide (SiC)

particulates between aluminium and tin produce a homogenous distribution of

reinforcement in the matrix. While other methods of production like casting have the

problems of reinforcement segregation and clustering, interfacial chemical reactions,

high localized residual porosity and poor interfacial bonding (Khairaldien et al.,

2007).

1.2 Problem Statement

This study is aimed to find out the answer for the following question which is the

dimension accuracy using sand casting produced part is not same as the master

pattern. Dimensional accuracy is very important when sand casting is applied

because if the final product not accurate, so the product will malfunction. However,

the study review of casting process by using different material aluminium and tin

reinforcement silicon carbide with indentifying the effect surface roughness. The

manufacturer needs to recreate back the casting process and it will cost more for

making the product.

3

1.3 Objective

The objectives of this research are:

i. To investigate the different material aluminium and tin reinforcement with

silicon carbide on dimensional accuracy and surface roughness using sand

casting.

ii. To identify the effect dimension accuracy and surface roughness using sand

casting.

1.4 Scope of the Project

This research will emphasize on the casting quality with surface roughness and

dimensional accuracy of aluminium and tin with reinforcement silicon carbide in

sand casting. The effect of surface roughness and dimensional accuracy according to

the different material through sand casting process with studied and explained in this

research. In this research used aluminium and tin reinforced with silicon carbide

composites in different structural applications. Other than that, production tool is an

important component of manufacturing which contributes to a process of designing

and developing the tools, methods and techniques necessary to improve

manufacturing efficiency and productivity.

The scopes study this project about the:

a) Material composition (Aluminium and Tin with reinforcement Silicon

carbide)

b) Casting quality (surface roughness and dimensional accuracy)

4

CHAPTER 2

LITERATURE REVIEW

2.1 Casting

2.1.1 Introduction

In this study, the basic casting principle of the most popular methods of producing

parts in metal is by casting. Casting is the process of forming objects by pouring

liquid metal into a cavity having the same shape as the finished article (the mould),

and then letting it solidify and cool. When removed from the mould, the casting

produced should be an exact replica of the mould (Frederick, 1996).

The casting process is little metal is wasted. In most early casting processes many

which are still used that be must destroyed in order to remove the product after

solidification. The used for permanent mould, which could be used to produce

component in endless quantities, was the obvious alternative (Edward, 2003).

5

The casting and solidification process involve pouring and cooling the liquid metal.

The information of the heat transfer and fluid mechanic occurring during pouring and

cooling is also necessary (Bibby and Beddoes, 2003). Often, the casting process are

important and extensively used manufacturing methods, enabling the production of

very complex or intricate parts in nearly all types of metals with high production

rates, average to good tolerances and surface roughness, and good material properties

(Alting, 1994).

Figure 2.1: Pouring molten metal into mould (Parashar and Mittal, 2007).

2.1.2 Sand casting

In this study, the type of casting method used the sand casting technique process .In

foundries; sand is used for making moulds. Natural sand found on the bed and banks

of rivers provides an abundant source, although high quality silica sand is also

mined. Sand is chemically SiO2 (silicon dioxide) in granular form. Ordinary river

sand contains a contain percentage of clay, moisture, non-metallic impurities and

traces of magnesium and calcium salts besides silica grains.

comparison of sand casting surface roughness and...

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