Manuf. Report 2010
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Transcript of Manuf. Report 2010
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REDUCTION BOX
Introduction
First of all we decided to make a reduction box in order to understand casting and
machining processes. The movement in reduction box will enter from point of A and it turn up
from point of B. We are trying to increase or decrease power by using this box.
Processes
1. Preparing GearsWe started our project by founding
two appropriate gears, we found two tractor
gears. (In the picture the gear on the right is
after the cutting process. And the left one is
before cutting)
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After that we measured the gears with vernier caliber. We write down all diameters and
dimensions of our gears. Now, two things are important for us, one of them is gears inner
diameter because we need to apply turning process in it and second important thing is gears
outer diameter since we have to place it into a box.
Because we have to think about our box and how we are
going to fit our gears in it so we have to think about
machining. First of all, we cut unnecessary outer parts of
our gears by using cutting machine. Final shape of our
gears can be seen in the picture above.
2. Preparing ShaftsBy using the inner diameter of our
gears, we found two cylindrical iron
parts to make our shafts. First of all we
reduced the length of two shafts by using
cutting machine as seen in the picture.
The cutting tool that we used to
cut gears unnecessary parts.
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Then we reduced the
diameter of one of the shafts and
equalized with the other shaft
diameter by using lathe machine
as seen in the picture.
Then we selected our bearings according to shaft diameters and bought them from the related
market. We will need them when placing gears and shafts into the box.
3. Preparing Pattern for Reduction BoxWe have drawn the shape of our box in solidwork for casting by using our shaft and gear
dimensions. We decided how the dimension should be, before drawing in solidworks we draw it
by hand on a plain paper with showing dimensions on it.
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By using our solidworks drawing, we went to woodshop and prepared our pattern from
wood. Wooden pattern seem more possible to make for us in Magosa, we make our pattern from
two parts because it is a complicated shape and one part would require big and complicated core,
which is almost impossible to make. We made it from five parts. Each for one side and another
part for the bottom of the box. Since two each sides are identically same, 3 parts of pattern will
be enough for us to make our casting, but we make the hole pattern which is five parts to see the
complete shape of our pattern box. Casting from three parts doesnt require any core. While
making our patterns we havent make holes in it for shafts since it is difficult to make the pattern
in that way and do the casting process with a pattern complicated with holes. We decided to
make the holes on two side of the box afterwards with machining on milling machine when the
casting is complete so we havent make holes on our pattern.
As can be seen from the photos we cut the wood in required dimensions and combined necessary
parts by screws.
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Finished pattern can be seen from
the photo. We make the pattern
piece by piece because it is not
possible to make it as a whole.
There are five parts ready for
casting operation as seen. Four
side parts and one bottom part.
We decided to make our reduction box from aluminum to carry the gears. We chose
aluminum because it has lower melting point temperature compare to most of other metals so
aluminum casting requires less temperature and it is more makeable in our case.
4. DifficultiesUnfortunately it wasnt possible for us to make it from aluminum because it is a very big and
large part so it was going to cost too much for us. It required 15kg`s of aluminum so we had to
leave our casting process for reduction box. Also we didnt have any alternatives in Magosa to
do our casting from any other proper material with cheaper cost. In order to understand casting
process we decided to make a sand casting process with a ready and simple pattern by using lead
in our workshop.
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SAND CASTING
OVERVIEW
In our project, our aim is to make a shape by sand casting and to practice what we have
learned. For sand casting, the most common metals used are iron, steel, bronze, brass and
aluminum. But we used lead (Pb) because it has low melting point and easy to use while casting
in our workshop. Sand casting can produce small parts that weigh less than one pound or large
parts that weight several tons. The process is used to make medium to large parts such as valve
bodies, plumbing fixtures, locomotive components and construction machinery. Its versatility
also allows sand casting to produce small parts such as buckles, handles, knobs and hinges. It is a
cost effective and efficient process for small lot production, and yet, when using automated
equipment, it is an effective manufacturing process for high-volume production.
Sand molds are created using various materials, the sand must be bonded together using
either synthetic compounds or clay and water and molds must be rebuilt after each casting.
The design of molds is a very complicated process; however, in general, they are filled
simply by gravity without the need for any pressure differentials or mechanical action.
Casting is generally the quickest way to produce either a small amount of prototypes or
very production quantities. The casting process is used by almost every industry as all metal can
be cast. Molten metal is poured into the mold cavity formed out of sand (natural or synthetic).
Many casting processes use patterns that form the cavity of the mold and can be made of
wood, plastic, metal or other materials. Pattern which are expandable (consumed by the mold
making process or by the poured metal during casting) are made of wax, plastic, or polystyrene
foam. Patterns are oversized to make up for metal shrinkage as it solidifies.
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PROCEDURES
Step 1
We prepared our sand mixture by sieving it into small parts by hand. Also, we used sieving
machine as seen for even more smaller sand particles. The more our sand gets smaller, the more
our final product gets good surface finish.
Step2
We placed our pattern in the middle of our flask part, we used some powder on to pattern. We
filled the flask with sand and applied some pressure on it to press the sand. We also used a metal
plate to smoothen the sand surface and we used powder again on it to easy separation of flask
parts.
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Step3
We turned upside down the flask part remaining cavity of the packed sand has desired shape of
our cast part. And we placed two metal cylinders for risers. Risers prevent this by providing
molten metal to the casting as it solidifies, so that the cavity forms in the riser and not the
casting. We closed second part of the flask. We filled the second flask part with sand too and
then we applied pressure on it and pressed the sand.
Step4
And then we removed the cylindrical parts. We separated the flask parts and removed our
pattern. We can use the pattern again in other casting operations. We make the runner between
the riser and the cavity.
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Step5
We closed the second flask part on it. We made our downsprue to prevent splashes. The cope
and drag are then combined and are ready to accept the metal.
Step6
Then we melted our lead metal (300 C) and prepared it for pouring. During this procedure we
cleaned the liquid lead by separating the obstacles from it. Then the molten metal is poured into
the mold.
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The part is allowed to sit and cool. Since, we used lead. Our metal solidified quickly so we only
waited a couple of minutes. Once the casting is cooled we destroyed the sand mold in order to
remove our part from the mold. The sand can be recycled for future processes. Then we removed
our part from risers and cleaned it from sand. And finally our part is ready.
Step7
We had our part made from lead in the
end but it needed some machining to
remove unnecessary parts. We used file
to remove them. We could have used
grinding machine to fasten the process
but since we used Lead it wasnt
possible for us to use it.
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OBSERVATION
We observed that sand casting provided us a good accuracy and good surface finish. It is
hard to produce complex part shape because making core is difficult and expensive. But in our
case, it was on easy procedure because we made a simple shape in order to understand the
casting process in general. Sand can be reused again, but a new sand mold must be made for each
part produced.
CONCLUSION
In this report we have tried to explain our work when making reduction box and casting
project. We had our shape in the end which is a thermometer base for decorative use which can
be considered to be in a good shape but it still needed some machining. We saw some errors in
our part, but our aim is not producing excellent parts. Our aim is just analyzing the errors in our
casted part. Usually a weight is put onto the part during and after pouring. But we havent
considered about it so we have some unnecessary part caused by molten lead flowing between
two flask parts. In other words we had some empty space between flask parts. So it needed some
job with the file. As a conclusion we can say that we saw our mistakes, we analysed our errors
and we finished our casting project.