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Investigation Of The Effect Of Moulding Sand (natural & Synthetic) On Casting Of Flange Using Aluminium
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CHAPTER ONE
1.0 INTRODUCTION
1.1 Background of the Study
Foundry
is a manufacturing process by which metallic products are formed by
preparation of mould, melting the required metal, pouring it into a
cavity formed by the mould and allow to solidify. In this way the
molten metal takes the shape of the cavity. This product is cleaned and
machined to desired dimension. Moulds can be made of metals or
non-metals but generally they are prepared in Sands.
(Oshungbure,
1998). Foundry Technology can also be described as the beginning and the
end of Engineering. Foundry Technology can best be described as
underdeveloped in Nigeria. Considering the fact that Technological
development of a nation is anchored on the state of her foundry
Technology. Knowing the fact that machine component even for further
production depends on the casting industry.
Thus, it can be rightly
said that, the country is still in the development process. Foundry
Technology cannot be said to really make impact in Nigeria until the
early part of the 1970’s when product of the industry were cast iron and
non-ferrous material like aluminium. Before this period, aluminium
product was the prominent product and then very few cottage foundry
workshop were around producing aluminum pots.
Foundry industries in
Nigeria have moved from its traditional arm chair status to a more
progressive, more customer emphatic and progress driven activity.
The
major issues that would drive foundry industry in this country are
globalization and Technology. One common thread that runs through this
issue is quality product for the customers is no doubt an imperative for
the foundry industry to meet the current and future challenges.
(Howard,
1959), Sand used to make moulds must be carefully conditioned and
controlled in order to give satisfactory and uniform results. Ordinary
Silica Zircon or Olivine are compounded with additives to meets some
requirements or alternatively Bentonite, Silica Sand and moisture with
additives will also meets some requirements.
Refractoriness is
provided by the basic nature of the sand, cohesiveness, bind or strength
obtain by coating the sand grains with clay, such as Bentonite,
Kaolite, illite that become cohesive when moistened. Collapsibility is
obtained by adding cereals or other organic materials that burn out when
exposed to the hot metal thereby reducing the volume of solid bulk and
decreasing the strength of the restraining sand. Permeability is the
ability of moulding sand to allow gasses to escape to atmosphere during
pouring of molten metal into a well prepared mould. Good moulding sand
always represent a compromise between conflicting factors, such as grain
size of the sand particles, the amount of bonding agents such as clay,
moisture content and organic matters combined so as to obtain a
satisfactory result. Consequently some factors must be carefully
controlled to assure satisfactory results. Sand control is little
concern to the designer of casting but, it is a matter of great concern
to the foundry worker who expected to deliver casting of good and
consistent quality.
In foundry practice, moulding mixtures of varied
composition are used. These multiple varieties result from the
varieties in the nature of the castings and the quality of input
materials.
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ABSRACT - [ Total Page(s): 1 ]This study tend to investigate the effect of synthetic and natural moulding sand on casting of flange like component. In this study FUTA logo was selected to be cast using aluminium metal. The casting was carried out and the result was analysed according to the quality of casting. It was discovered that for large size component using aluminium, it is better to use synthetic sand and which is hereby recommended for casting Aluminum large size component. ... Continue reading---
