Design and Development of A Centrifugal Casting Machine For Pistons Production

DESIGN AND DEVELOPMENT OF A CENTRIFUGAL CASTING MACHINE FOR PISTONS PRODUCTION
DESIGN AND DEVELOPMENT OF A CENTRIFUGAL CASTING

MACHINE FOR PISTONS PRODUCTION
Mechanical Engineering Department, Faculty of Engineering Imsu owerri.
Abstract
This presentation concerns to the development of a centrifugal casting equipment to produce

engine pistons with gradient of properties. Pistons require different properties in different
areas of their body, such as high thermal fatigue resistance in the top, high wear resistance in
the pin-bore area and low weight in the skirt. Reliable processing techniques for that purpose
have not been established yet, and results obtained so far reveal sharp and undesirable
interfaces. A possible solution might be a well controlled sequential pouring technique of
different materials that lead to a smooth gradient of composition/properties between different
piston functional areas, using centrifugal casting. For this purpose a special design of a
vertical axis centrifugal casting machine was developed. A detailed study of the centrifugal
pouring process and the inherent fluid dynamics was performed to develop a conceptual
design and operation parameters and input/output system variables were established. A
sketch of the equipment was developed and established the main components and
interconnections. Finally, the design and selection of the systems components was done
accordingly to the main goals of this work. This paper analyses and discusses all of the
referred design phases, including selection and prototype implementation of the necessary
actuators.
Keywords: Mechanical design, Motor pistons; Castings; Functionally materials
ABSTRACT
CHAPTER 1
1.1 Introduction .. 3
1.2 Background Of Study ...... 4
1.3 Definition Of Problem . 5
1.4 Scope And Objective of Study . 5
CHAPTER 2
2.1 Literature Review ... 7
CHAPTER 3
3.1 Conceptual Design .... 8
3.2 Mould .... 9
3.3 Centrifugal Equipment ..... 10
3.4 Alternative Proposed For the Conceptual Solution... 10
CHAPTER 4
4.1 Detailed Design . 12
4.1.1
Transmission (Off the Shelf) .. 12
4.1.2
Plate .... 12
4.1.3
Isolated Joint (off the shelf)..... 13
4.1.4
Shaft .... 13
4.1.5
Bearing (Off The Shaft) .. .. 13
4.1.6
Anti-Vibration System (off the shaft)..... 14
4.1.7
Machine Structure .. 14
CHAPTER 5
5.1 Maintenance 16
5.2 Information on Maintenance 17
CHAPTER 6
6.1 Conclusion
6.2 References
Chapter-1
1.1 Introduction
Metal casting is the oldest industries in the human society. The art of foundry is as ancient as
the dawn of the civilization. Even the craftsmen of the Greek and Roman civilization had
practiced the art of foundry. A casting may be defined as a "metal object obtained by
allowing molten metal to solidify in a mold", the shape of the object being determined by the
shape of the mold cavity [Hiene, 1955]. The strength of the foundry industry lies in the fact
that, the casting process allows metals to take the shapes that will serve the need of the
humans.
Casting, or reforming materials by heating, melting and molding, can be traced back in
history six thousand years. As civilization progressed and the use of metals became more
advanced, the technology of casting metals advanced as well. As foundry industries began to
demand higher yields and better physical properties from cast metal products, casting
processes became more specialized.
The centrifugal casting method was developed after the turn of the 20 th century to meet the
need for higher standards. The process of centrifugal casting differs from static casting in that
the mold itself is spinning during the time, casting is solidifying. Centrifugal castings are
usually poured while the mold is spinning; however, for certain applications, particularly in
the case of a vertical casting, it is sometimes preferable that the mold be stationary when
pouring begins. The machine then accelerates the speed of the rotating mold either during the
filling of the mold or after completion of pouring. In other cases, such as horizontal
centrifugal casting, it is often desirable to have the mold rotating at a lower speed during
pouring, followed by rapid acceleration to a higher speed during the solidification period.
The application of centrifugal force to a molten metal as it solidifies can be used to achieve a
dense, sound casting. The centrifugal casting process is most widely used for manufacturing
of cast iron tubes, pipes, cylinder liners and other axis-symmetry parts.
1.2 BACKGROUD OF STUDY

The centrifugal casting process consists of pouring the molten metal at a suitable
temperature into a rapidly rotating mould or die. It is essential that pouring
temperature of molten metal should be high enough to enable it to reach the farthest
point in the mould before solidification commence. The axis of rotation of mould
may be horizontal, vertical or slightly inclined. The centrifugal force imparted to
molten metal enables it to be picked up and held in contact with the rotating mould.
The mould is allowed to rotate till the casting is completely solidified. Thus the
outer shape of casting takes the shape of the inside of the mould and the bore of
casting is truly circular and concentric with axis of rotation. The thickness of casting
is determined by the quantity of molten metal poured, and the length by the length
of mold between two end plates. In case of centrifugal casting, there is no need of
runners and risers [Paranjpe, 2001]. The metal in the bore serves as riser. Therefore,
the yield from centrifugal casting is much higher than normally obtained in gravity
poured castings because there are neither separate gates nor risers. The castings thus
produced also have a high density than that of gravity poured castings, and have the
superior mechanical properties [Paranjpe, 2001].
Fig1.1. Schematic of centrifugal casting process [Gao et

al, 2000]
1.3. DEFINATION OF PROBLEM

In centrifugal casting, it is very difficult to determine the temperature distribution
and solidification time by experimental techniques. Because of this, accurate data on
solidification time during centrifugal casting of different materials is not available.
Their estimation is a complex problem mainly because the moving particles disturb
the temperature equilibrium. Due to liquid and solid region in the casting during
solidification, there is difference in thermo-physical properties of different regions
of casting during solidification.
1.4.
SCOPE AND OBJECTIVES OF STUDY
The major scope and objectives of this topic objectives are :

To understand the physics of the solidification process of centrifugal casting.
To identify the various factors affecting solidification process of centrifugal castings.
To be able to have the theoretical knowledge or background knowledge on the design
and construction of centrifugal casting machine for piston production.
CHAPTER - 2
2.1 LITRURE REVIEW
Pistons require different properties in different areas of their body, such as high thermal
fatigue resistance in the top, high wear resistance in the pin-bore area and low weight in the
skirt. On our days, they are not pistons with composition gradient. The pistons are usually
produced with homogeneous composition, in one alloy, existing in some cases incorporations
of another material, to improve the mechanical characteristics in certain area (as for instance
in the grooves for the segments).
The pistons are typically produced by gravity casting, in metallic mould and afterwards
machined. However, in special cases, pistons are manufactured by forging to increase their
mechanical properties.
Relatively to the centrifugal casting, this technique has been mainly used for obtaining
cylindrical parts. There are essentially two basic types of centrifugal casting machines: the
horizontal types, which rotate about horizontal axis, and the vertical type, which rotates
about a vertical axis (see figure 1).
Horizontal centrifugal casting machines are generally used to make pipe, tube, bushing,
cylinder sleeves (liners), and cylindrical or tubular casting that are simple in shape. The
range of application of vertical centrifugal casting machines is considerably wider: gear
blanks, pulley sheaves, wheels, impellers, electric motor rotors, valve bodies, plugs, yokes,
brackets [5]. Casting that are not cylindrical, or even symmetrical, can be made using vertical
centrifugal casting. Centrifugally cast parts have a high degree of metallurgical cleanliness
and homogeneous microstructures, and they do not exhibit the anisotropy of mechanical
properties evident in rolled/welded or forged parts [6, 7].
a)
b)
Figure 1. Centrifugal casting types: (a) horizontal axis and (b) vertical axis [8 ,9].
Due to the referred advantages of this process, a possible solution for the pistons production
might be a well-controlled sequential pouring technique of different materials that lead to a
smooth gradient of composition/properties between different piston functional areas, using
7
centrifugal casting. This paper shows the special design performed to develop a vertical axis
centrifugal casting machine for that purpose.
With the purpose to achieve the project goals, the design specifications were firstly
established, based on the opinion of the futures users. Then a detailed study to characterize
the state of the art of centrifugal casting machines was carried out. Afterwards, the
conceptual design was performed, established the operation parameters, as well as, the input
and output system variables. In this phase of the project, a sketch of the equipment was made
with the definition of the main components and their interconnections. Finally, the design
and selection of the systems components was performed accordingly.
CHAPTER-3
3.1Conceptual design
The main objective of this work is the design and development of an equipment capable to
perform the permanent casting of pistons with gradient of composition. Figure 2 shows the
piston virtual model that it is intended to produce.
Figure 2. Motor piston geometry.
The piston base geometry and the pin hole will be obtained by casting and the final surface
finishing and the rings grooves will be made using traditional machining processes.
It is specification of this work that the castings should be obtained in a metallic mould, using
the vertical axis centrifugal casting technique. In what concerns to the centrifugal equipment,
it must guarantee a variable rotation speed between 300 and 2000 rpm.
This way, the goals of this equipment design appear as twofold: Design of the centrifugal equipment; - Design of the
metallic mould.
The operation principle of the developed equipment is schematized in the figure 3. It consists
in a metallic mould that it is put into rotation using a motor and a belt. During the rotation
movement the different alloys are poured, in a sequential way, which will create different
composition in the piston functional areas. In the precise moment shown in the figure two
alloys are being simultaneous poured. This situation corresponds to the transition phase
among the materials, in order to create the composition gradient.
Figure 3. Schematic representation of the proposed pistons production device.
The liquid metal, when being poured in a mould in rotation, is submitted to a centrifugal
force that originates a pressure increase, which impels the metal against the mould walls,
where it solidifies.
By attaching the casting mould to the centrifugation equipment a machine capable to carry
out the centrifugal pouring is obtained.
3.2 Mould
Being one of the most important machine components, the mould design is crucial to reach a
good result during the liquid melt pouring. This result will be evaluated by the quality of the
obtained pieces, namely the presence of defects occurred during pouring and solidification,
and for the ability to handle the Mould and the poured pieces. This way, the mould design
involves the development of the mould geometry, cores, and pouring system.
The mould geometry and the cores determine the final geometry of the poured pieces.
Concerning the pouring system, it is designed with the purpose to create the ideal conditions
for the metal pouring and filling of the mould cavity, in order to obtain sound pieces with the
desired composition gradient.
3.3 Centrifugation equipment

The main function of the centrifugation equipment is to supply rotation movement to the
mould. However, given the intended rotation speed range and mainly the involved mass, this
system has to accomplish certain safety and stability conditions, to guarantee its
effectiveness. Thus, the centrifugation equipment design must attend to the following parts:
- Motor;
- Mechanical transmission;
- Mould attaching;
- Bearings units; - Anti-vibration systems;
- Machine support structure.
10
3.4 Alternatives proposed for the conceptual solution

Initially, attending to the design requirements and specifications and to the state of the art,
some alternatives for the conceptual solution were proposed. Figure 4 shows the several
hypotheses that were considered during the initial design phase.
In the first case, figure 4a), it was proposed a direct connection between the motor and the
plate that holds the mould. In the second case, figure 4b), a gears transmission and in the last
case, figure 4c), a belt transmission.
a)
b)
c)
Figure 4. Alternatives considered for the conceptual solution.
Table 1 synthesizes the main advantages and disadvantages of the three solutions presented
previously.
Advantages
Solution 1- Less components
Disadvantages
- High vibration in the shaft
- Compact
Solution 2- Structural rigidity
- Inexistence of flexible elements
Solution 3- Low vibrations
- Larger stability in the movement
11
- High noise
- Difficulty in absorbing vibrations
- Belt maintenance
Table 1 Main specifications analysis for the different solutions.

In agreement with a specifications optimization process, the solution 3 (belt transmission)
was selected for the vertical axis centrifugal casting equipment.
CHAPTER 4
4.1 Detail design

The final solution, which was obtained after considering several design iterations, is
presented in figure 5, where the main equipment components can be identified. These
components will be described in the next topics.
The equipment operation principle can be briefly described as follows: The mould is attached
to a metallic plate using M6 screws. The rotation of the plate is obtained through the shaft
that is attached to a transmission system that includes a motor, two pulleys and a
transmission belt.
The plate motion stability is assured by two bearings placed in the shaft (enclosed by a
metallic cylinder) and by the anti-vibration base. A structure shell is the housing for the
overall equipment, using a tube and a metallic sheet, to guarantee the safety of the
equipment.
12
Figure 5. Squematic representation of the adopted solution.
4.1.1 Mould The mould (figure 6) has a parallelepiped form with capacity to pour two
pistons. It is divided in two half parts, and it has in its interior two cores. The cores are fixed
by pins trunk conics and for the mould. Each piston (oriented outside) is poured through the
skirt using two pouring channels of square section. In the superior half-die a pouring basin
made of thermo set sand is used to allow the cut of the sprue when the piece is removed.
Figure 6. Casting mould.
13
4.1.2 Transmission (off the shelf) - The transmission (figure 7) includes a 3-phases motor,
two pulleys and a belt. An inverter is used to allow the regulation of the motor rotation speed.
The movement transmission between the moved pulley and the machine shaft is carry out by
a key.
Figure 7. Motor, pulleys, belt and inverter.
4.1.3 Plate A key assures the movement transmission between the shaft and the plate. This
plate (figure 8) is the component where the mould is attached; it has thread holes for its
fixation. Finally, the plate geometry was design in order to minimize its mass/weight.
4.1.4 Isolated joint (off the shelf) The isolated joint (figure 9) is made in rockwool
material. It is located between the mould and the plate to minimize the heat transfer between
the mould and the other equipment components, since high temperatures could damage them,
namely the belt.
4.1.5 Shaft - The shaft (figure 10) it is the most complex piece of the whole equipment, once
it is composed by three parts: the superior and inferior sections and the thread union. The
superior section serves as a guide and movement transmission for the pulley and the plate.
On the other hand, the inferior section, guarantees stability to the system during rotation, and
it is where bearings are attached. The union between both sections is made by a thread cover,
as shown in the same figure.
14
Figure 8. Plate.
Figure 9. Isolated joint. Figure 10. Shaft.
4.1.6 Bearings (off the shelf) - Bearings (figure 11) were used to allow the relative
movement between the rotative group and the machine support. Two bearings types are used;
one of deep groove ball type and another of taper roller type (supports radial and axial
strengths). Bearings assembly is made by tighten between the shaft and the metallic cylinder.
4.1.7 Anti-vibration system (off the shelf) Outside, bearings are surrounded by a metallic
cylinder. This cylinder is independent of the rigid structure of the machine. There is a small
space among both, that allows the placement of the anti-vibration systems. These systems
have the function to absorb those shocks originated by the shaft and to avoid, this way, the
vibrations propagation into the machine structure. The anti-vibratory system is constituted by
anti-vibratory bases (figure 12) and a foam blanket of high density (figure 13) located in the
base.
15
Figure 11. Bearings.
Figure 12. Anti-vibration

base.
Figure 13. Anti-vibration blanket.
4.1.8 Machine structure - The structure has two fundamental functions: to serve as support
to the machine, to promote the operator safety and the equipment protection. The support
function is guaranteed by some supports in steel, as can be see in the figure 5. On the other
hand, the protection function is obtained with square section tubes and sheets that cover the
whole machine. The structure still has a service hatchway that allows the access to the
mould.
16
CHAPTER 5
5.1 MAINTANANCE
The Super Cast casting machine is equipped with devices and a software that can
signal functioning errors on the display. They make the easier service work.
1)
Over-temperature of the water cooling:

This signalling indicates that the thermostat inserted in the water cooling
input withdrawn by the internal tank (25 litres) has detected a temperature
of 65C. To protect the machine, the operation is stopped until the
temperature of the water goes below 60C. Possible causes in order of
probability and priority of research:
Around 15 consecutive castings have been performed with elevated power
of heating and high temperature. In this case, it is necessary to wait until the
water cools. External cooling systems are available with greater volume of
available water, which allow making a greater number of consecutive
castings without stopping the operation.
If the temperature of water in the inside tank is sufficiently below 65C, the cause is
due to a thermostat damage.
2)
Insufficient flow of the water cooling:
This signalling indicates that the sensor of measure of the water flow to the
discharge has detected a flow under to about 2 lt/mins.
To protect the machine, the operation is stopped until a water flow over 2 litres/min is
restored.
Possible causes in order of probability and
priority of research: the circulation pump
doesn't work correctly presence of
17
obstacles in the hydraulic circuit of the

machine water's leak along the hydraulic
circuit blocking or damages of the water
flow sensor
Under voltage of the power supply:

This signalling indicates that the control circuit that measures and controls the
electric voltage supplied by the power supply net has detected a tension, also
temporary, under 180VAC, dangerous for the operation of the circuits and the
electric components that are equipped with the machine.
Consequently, the operation is completely blocked until the regular working conditions
are restored.
Possible causes in order of probability and priority of research: power supply
voltage is reduced compared to the nominal value (220 - 230 VAC) non
suitable power supply net for the loads to be supplied, with notable drop of the
power supplied from empty to load.
To identify the cause of the problem, it is necessary to measure the voltage with
an AC Voltmeter under all the operational conditions: before starting the
machine and also under the conditions of maximum electric load (power at
100% and simultaneously at starting of centrifuge).
5.2 INFORMATION ON THE MAINTENANCE

ATTENTION:
BEFORE MAKING ANY MAINTENANCE OPERATION, DISCONNECT
THE MACHINE FROM THE ELECTRIC SUPPLY.
Clean carefully inside the centrifugal chamber removing any investment,

fragment or metal splinter.
18
Check every 6 months that water level in the cooling tank and refill the
water evaporated during the use of the casting machine through the
appropriate cap, accessible removing the back side panel.
Check the oil level in the vacuum pump at least once a year.
Conclusions
The design and development of a centrifugal casting machine to produce motor pistons has
been presented and discussed throughout this work. A simple equipment of feasible
construction, adaptable to different processing conditions was obtained, fulfilling the initial
specifications and safety standards.
The main merit of this project is its innovative equipment concept, when compared to those
available in the market with special interest for the Functionalized Graded Materials (FGMs)
research field and constitute a fundamental and important contribution for the research and
development of new pioneering centrifugal casting products.
This paper highlighted the design phase carried out so far, and future work will be focused on
the detail design validation, as well as to the implementation of the overall (electronics
hardware and software) systems architecture to monitor and control the testing apparatus.
19
References
Noda T., Application of cast gamma TiAl for automobiles, Intermetallics, Vol. 6, 1998,
pp. 709-713.
Sherman A.M., Froes F.H., The use of titanium in production automobiles: potential and
challenges , JOM, 1997, pp.42-44.
Gebauer K., Performance, tolerance and cost of TiAl passenger car valves,
Intermetallics,
Vol. 14, 2006, pp. 355-360.
Si-Young S., Young-Jig K., Economic net-shape forming of TiAl alloys for automotive
parts, Intermetallics, Vol. 14, 2006, pp. 1163-1167.
20
Chirita G., Soares D., Silva F.S., Advantages of the centrifugal casting technique for the
production of structural components with AlSi alloys, Materials and Design, Vol.
29, 2008, pp. 2027.
Liu G., Ma Y.C., Gao M, Rao G.B., Li Y.Y., Wei K., et al., Single step centrifugal casting
TiAl automotive valves, Intermetallics, 2005, Vol. 13, pp. 9258.
Halvaee A., Talebi A., Effect of process variables on microstructure and segregation in
centrifugal casting of C9220 alloy, J Mater Proc Technol, 2001, pp. 118,1237.
Without author, Metals handbook: Casting, Vol. 15, ASM International, 9edition, 1998.
Janco, N., Centrifugal Casting, AFS, Illinois, 1998.
21

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DESIGN AND DEVELOPMENT OF A CENTRIFUGAL CASTING MACHINE FOR PISTONS PRODUCTION