Modification Of An Existing Metal Sheet-bending Machine

CHAPTER FOUR
COMPONENT DESIGN AND CONSTRUCTION
    Sand casting is one of the quickest and most cost effective methods adopted in the production of metal prototypes and is an excellent solution for low to medium run of pasts that do not require a specific or precise shape repeatability.
    The summary of making  a cast material using sand casting process are as follows.
1.    A mold was created by placing the mixture of sand, clay and water on a pattern, and when the pattern was removed the clay had a cavity that corresponds to the shape of the pattern.
2.    The sand molded has two parts, the upper part is known as the cope while the bottom one is called the drag.
The molds are encased in a two part but called a flask for protection. Before the flask was closed, sand cores needed to manufacture the part details are placed in the mold halves. The getting system was placed inside and a sprue is formed in order for the molten alluy to be fed into cast
3.    The two halves were closed and clapped together and the motten metal produced due to melting of different alluys is then poured into the mold. As the motten metals starts to cool. Contraction takes place and molten metal is fed in from the risers that were placed in the casting system.
4.    After a present dwell time the metal solidified, the cast shacked out took place and the heat from the motten metal that to poured into it dires out the moisture making the cast easy to crack open when the metal has cooled. The dimension of the cast made are! Length 245mm, breadth 145mm and height 17.5m.
5.    After the making of the cast there was sand particle sticked all round the cast material made and for the removal of the sand particles, the cast to have a précised shape of where the cast will be fitted into.
6.      After machining operation on the shaping machine, the cast (work piece) was transferred toteh horizontal milling machine for creating a flat surface on the cast and for minking a slot for the successive operation of a flat surface on the work pieced we use a front and slide mill cutter as the cutting fool. We used an end mill cutter to make slot of length 178mm by Breadth of 24mm on the cast (work pieces).
7.    After machining operation on the milling machine, the cast (Work piece) was transferred to the pillar or column drilling machine for creating a hole of 23mm diameter which an internal threading will be threaded through it.
8.     The cast (work piece) was mounted on the table vice for internal threading operation on the already drilled hole. For the internal threading to be successive we use a tap of 24mm since the drilled hole is 23mm for the threading to be accurate and perfect for the bolt to be tied with a nut when fitting the cast.