Sand Mould Design for Casting an Aluminium Pot-A Basic Procedure of Supplementing Artisanal Practices

##plugins.themes.bootstrap3.article.main##

  •   Thomas Ndyar Guma

  •   Lilian Ogboi Uche

Abstract

Artisanal green sand casting of aluminum pots is a notable flourishing business in many urban areas of west and central Africa but seen to be typified by labor-intensive and subjective control of a large number of variables to successfully cast. Correct mold designs with in-flow and cooling rates of molten aluminum are fundamental in reducing labor and defects in the castings. The paper presents sand mold design for casting 30litre-capacity cylindrical aluminum pot of internal diameter 314.7mm, depth 386mm, and wall thickness 4mm with  handling lugs alongside its cover using unpressurized gating system ratio of 1:3:3. The design provides suitable specifications of the ladle position, mass and pouring time and in-flow rate of molten aluminum, layout for the mold components, means of compensating process cooling shrinkages of aluminum during solidification, patterns for the castings, and molding box. The motive behind the paper was to emphasize and exemplify the use of basic engineering design procedure for supplementing artisanal green sand molding practices for improving consistency and productivity, and minimizing laboriousness and casing defects with improved profitability in the business.


Keywords: Green sand casting business, subjective mold designs, consistency, laboriousness and scraps, profitability, engineering supplementation, improvement.

References

. Sand Casting Process, Defects, Design - CustomPartNet www.custompartnet.com/wu/SandCasting Extracted 29/07/2018

. J. Glownia. ‘’Metal Casting and Moulding Processes’’, in Koshal, D. (Ed), Manufacturing Engineers Reference Book. Oxford UK, Butherworh-Heineman Ltd, 1993, ch. 3, pp. 3-23.

. R.K.. Jain Production Technology, Delhi. India 16th Edn. Khanna Publishers, 2005, pp. 138-254.

. B. Avalon and T. Baumeister. Standard Handbook for Mechanical Engineers, London, Mcgraw-Hill Company, 1998, ch. 13, pp. 1-6.

. Sandcasting-nptel nptel.ac.in/courses/107103012/module2/lec1.pdf Extracted 02/06/2018.

. Sand Casting Design Rules-Sites at Penn State https://sites.psu.edu/shapelab/files/2017/.../Trad_Casting_Rules_Santosh-2kkxcb8.pdf Extracted 17/06/2018

. T. N. Guma (December 2010). Effect of Illo clay and corn flour additives on the foundry properties of Kaduna river sand in Nigeria. Journal of Chemical, Mechanical and Engineering Practice [Online] 1 (2 & 3). pp 1-7. Available: http://www.icidr.org/

. T.N. Guma (December 2012). Characteristic foundry properties of Kaduna river sand. Research Inventy International Journal of Engineering and Science, [Online] 1(11) pp. 3-8. Available: http://www.researchinventy.com/v1/11.html

. Ogboi Lilian Uche. “Sand casting design, production and testing of a 30-Litre capacity aluminium pot using locally available materials in Kaduna,” PGDME project report Dept of Mech. Eng. Nigerian Defence Academy, Kaduna, Nigeria, 2018.

. S. Santhi, B. Ramakrishna Surya, S. Jairam, J. Jhansi and P. K. S. Subramanian (January 2015). Design of gating and riser system for grate bar casting. Indian Foundry Journal [Online] 61(1), pp.19-23. Available: http://www.researchgate.net/publication/278330128_design_of_gating_system_and _riser S

. Victor Anjo and Reyaz Khan (July-December 2013). Design of gating system for casting thin aluminium alloy (Al-Si) plates. Leonardo Electronic Journal of Practices and Technologies [Online] 12(23), pp. 51-62. Available: ejpt.academicdirect.org/A23/051_062.htm

. C. M. Choudhari, Nikhil S. Dalal, Akshay P. Ghude1, Pratik P. Sankhe, Ashutosh M. Dhotre (April 2013). Design and analysis of riser for sand casting. International Journal of Students’ Research in Technology & Management [Online] 1(2), pp. 176-191. Available: http://www.ijsronline.net/aboutus.asp

. Nandagopal M, Sivakumar K, Senthilkumar G, Sengottuvelan M [November 2017]. Study of Sand casting gating system. International Journal of Recent Engineering Research and Development [Online] 2(11), pp.19-26. Available: http:/www.ijrerd.com

. Kiran R. Jathar1, Anant V. Hankare, Amol A. Sapkal [March 2017]. Gating system and feeder design of aluminum alloy (AA6063) casting for rectangular component. Journal of Advances in Sciences and Technology [Online] 13(1), pp. 35-40. Available: http:/www.ignited.in/j/jast

. Table of Physical &Chemical Properties, Chapter 2, General Physics, Section 2.2 Mechanical properties of materials, Subsection 2.2.3 Viscosities [Online]. National Physical Laboratory (NPL) Kaye & Lab. Available: http:/www.kayelaby.npl.co.uk/general.physics/

Downloads

Download data is not yet available.

##plugins.themes.bootstrap3.article.details##

How to Cite
[1]
Guma, T. and Uche, L. 2019. Sand Mould Design for Casting an Aluminium Pot-A Basic Procedure of Supplementing Artisanal Practices. European Journal of Engineering Research and Science. 4, 4 (Apr. 2019), 24-30. DOI:https://doi.org/10.24018/ejers.2019.4.4.1188.