Abstract:
This paper represents a systematic finite element analysis to evaluate the various mechanical
vibration impacts on sand mold casting during aluminum alloy cooling. In general, the mold
materials govern the molten metal filling of the cavity in a smooth, uniform, and complete manner.
Two distinct types of binding materials were used in this study. As a sand binding material, rubber
seed oil and cottonseed oil were utilized. The bottom gating system is adopted because of its low
gas entrapment and low surface defect features. Experimentation with several binders at various
mechanical vibrations was carried out, as well as computational analysis to determine the best
mechanical vibration range for the binders utilized. Following the application of mechanical
vibration, the coarser dendrites transformed into fine equiaxed grains, and the size, morphology,
and distribution of the -Al primary phase and eutectic silicon particles, as well as the SDAS, were
all significantly improved. The mechanical properties and density of A356 aluminum alloy
improved significantly as a result, with the tensile strength, yield strength, elongation as well as
hardness of the sample with 40 mm wall thickness measured to be 35% higher, 42% higher, 63
percent higher, and 29% higher than those of the conventionally cast sample under the T6
condition. The degree to which mechanical vibration had an effect on the microstructure and
mechanical properties of the material increased as the wall thickness increased. Following the
application of mechanical vibration, the coarser dendrites transformed into fine equiaxed grains,
and the size, morphology, and distribution of the -Al primary phase and eutectic silicon particles,
as well as the SDAS, were all significantly improved. The mechanical properties and density of
A356 aluminum alloy improved significantly as a result, with the tensile strength, yield strength,
elongation as well as hardness of the sample with 40 mm wall thickness measured to be 35%
higher, 42% higher, 63 percent higher, and 29% higher than those of the conventionally cast
sample under the T6 condition. The degree to which mechanical vibration had an effect on the
microstructure and mechanical properties of the material increased as the wall thickness increased.
The best binder was chosen based on the rate of cooling at a certain mechanical vibration range.
Solid works were used to create a CAD model and a fluid flow study was performed to confirm
the impact. The simulation parameters and boundary conditions were taken from an existing
model. The actual experimental situation results and CFD modeling both were to demonstrate
which binder is the most effective and at what mechanical vibration range does the binder cool
more quickly.
Description:
Supervised by
Prof. Dr. Md. Anayet Ullah Patwari,
Head,
Department of Mechanical and Production Engineering (MPE),
Islamic University of Technology (IUT),
Board Bazar, Gazipur-1704, Bangladesh.
This thesis is submitted in partial fulfillment of the requirements for the degree of Bachelor of Science in Mechanical and Production Engineering, 2022.