Manufacturing Presentation final-11.pptx

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1. Sand Casting Project Manufacturing Processes [Fall 2022] Course Instructor: Dr. Jamil Renno. Course TA : Engineer Ayman Salem Group 01 Team Members : Mohammad Saeed Ahmed Domi Mohamed Alhag Mohamed Abdelmoati

2. Presentation Outline Project Background Introduction of Selected Item 3D Model in SolidWorks 3D Printing Sand mold design Casting Surface finishing

3. Project Background Objectives (Problem statement): Create a 3D part of choice and print it Prepare a mold for sand casting Casting the product and Surface finishing Overall view of Project Progression: Objectives were achieved in sequence, in the form of weekly milestones achieved Each step was a learning experience ( better understanding)

4. Selected Item (Bracelet Holder/Door handle) The selected part was simple and complex simultaneously - Simple Modelling, Dimensioning and Scaling - Complex and precise curved geometry - Part could be sand cast The part is both artistic and functional It can function as either a bracelet/watch holder or a door handle It looks aesthetically pleasing, and so it is artistic Did you consider several versions of the item before you reach the final version? Several versions (of the part) were not considered due to minimal prior sand-casting experience and the decision to replicate the part exactly.

5. CAD Model Features Used: Using Swept Boss/Base (Circular profile) Fillets and Chamfers Design for casting Philosophy: Split the part into two halves at the correct plane Dimensioned the design considering the size of the flask and casting components as constraints Considered a possible orientation and used minimal details (to avoid damaging the mold during removal) Considered draft angles on the product (only as chamfers) and the sprue, risers, and gates (More not required because of the product’s geometry)

6. 3D Printing The parts were printed fast and with no defects Dimension accuracy was also good as expected The surfaces produced had a layered finish (3D printing characteristic) The design was scaled down at this stage to save material (for both the 3D printer and the casting material used)

7. Sand Casting and Mold Design How did you design the sand mold? The process was done by using our 3D printed pattern, sprue, and riser and plugging it in a sand-casting flasks. To begin with we start by adding the parting powder. Then we pour sand in both sides of the flask while plugging the sprue and riser on one side. While pouring the sand in either side “ Cope, Drag” we make sure to hammer the sand to obtain a smooth sand surface which does not breakoff while doing the sand casting or during the flipping action to obtain the sand cavity. Afterwards, when we get the sand mold ready, we remove the 3D printed pattern and connect both sides of the flask together “ Note: now the sand cavity is already created which is why we don’t need the 3D printed part.” Then we pour the molten metal through the sprue hole. Afterwards, the material is cooled down using water after solidification. Finally, we breakoff the product from the sand flask.

8. Sand Casting and Mold Design

9. Surface finishing Demonstrate your surface finish? After the sand casting we started the process of surface finishing which took a long time. The tools we used to get the surface finishing done was sand papers and filing tool. Sand papers and filing are used in order to get a polished and smoothed surface. We also use them to get rid of materials.

10. Sand Casting and Mold Design

11. Defects Causes Bending ( WaRPING ) Sudden change in temperature as the product is small and cooled rapidly Porosities Due to shrinkage. They have angular shape with rough walls.

12. Defects Pictures Bending Porosities

13. Shrinkage ( Solid Work – Reality )

14. Error percentages due to shrinkage

15. References https://www.researchgate.net/publication/292920895_Effect_of_slow_cooling_process_on_microstructure_and_properties_of_C-Mn-Cr_cold_rolled_dual_phase_steel