J COMPONENT REPORT

METAL CASTING TECHNOLOGY

(MEE2014)
CASTING AN ALUMINUM UPRIGHT WITH THE HELP OF SILICON
AND SILICA ALUMINUM CASTING

-By

Arjun Gupta (19BME1015)

Shashwat Vishwa (19BME1058)

Aporv Mathur (19BME1322)

Bhanu Pratap Singh (19BME1325)

Under the Guidance of

Dr. Senthil Kumar

SCHOOL OF MECHANICAL ENGINEERING

VELLORE INSTITUTE OF TECHNOLOGY, CHENNAI

1
 BONAFIDE CERTIFICATE

Certified that this project report entitled “CASTING ALUMINUM UPRIGHT

WITH THE HELP OF SILICON AND SILICA ALUMINUM CASTING”
is a bonafide work of “Arjun Gupta (19BME1015), Shashwat Vishwa
(19BME1058), Aporv Mathur (19BME1322) and Bhanu Pratap Singh
(19BME1325)” who carried out the project work under supervision and
guidance of Dr. Senthil Kumar for MEE2014 – Metal Casting Technology.

2
 ABSTRACT

Cost efficiency is a great concern while choosing aluminum upright. The

machining costs are high while the space required is also large. Through a
Silicon and silica casting prototype testing, we can fix the cost problems and
simply the manufacturing and machining of an upright.

3
 ACKNOWLEDGEMENT

We wish to express our sincere thanks and deep sense of gratitude to our project
guide, Dr. Senthil Kumar, Professor, School of Mechanical Engineering, for
his consistent encouragement and valuable guidance offered to us in a pleasant
manner throughout the course of the project work. We are extremely grateful to
Dr. Sreekant. D, Dean of School of Mechanical Engineering, VIT Chennai, for
extending the facilities of the School towards our project and for his unstinting
support. We also take this opportunity to thank all the faculty of the School for
their support and their wisdom imparted to us throughout the course. We thank
our parents, family, and friends for bearing with us throughout the course of our
project and for the opportunity they provided us in undergoing this course in
such a prestigious institution.

Arjun Gupta Shashwat Vishwa

Aporv Mathur Bhanu Pratap Singh

4
 TABLE OF CONTENTS

S. No. CONTENT Page No.

Abstract 3

Acknowledgement 4

1 INTRODUCTION

1.1 Problem statement 6

1.2 Objective 7

1.3 Benefits 7

2 ALUMINUM UPRIGHT

2.1 APPARATUS REQUIRED 8

2.2 PROCEDURE 8

2.3 DESIGN 9

2.4 GENERAL CALCULATIONS 10

2.5 MATERIAL DETAILS 11

2.6 DETAILED DIMENSIONS 12

2.7 SOFTWARE 13

3 RESULT, CONCLUSION and 15

FUTURE SCOPE

5 REFERENCES 18

5
 INTRODUCTION

 Casting is a manufacturing process in which a liquid material is poured

into a mold that normally contains cavities of the desired shape and then
solidified.

 The solidified part is called casting and is ejected or disassembled from

the mold to complete the process.

1.1 Problem Statement

Prior to this idea, all posts were CNC machined from aluminum blocks, but
due to the large size of the aluminum blocks, the machining costs were
enormous. Fixed and most materials are machined to reduce costs, so we are
trying to reduce the cost of upright production.

6
1.2 OBJECTIVE

 The objective of this project work is to create a mold from silica gel upon
an existing model of the upright and then using the created mold to cast
aluminum upright.

1.2 BENEFITS

 Cost efficient

 Technical efficiency with less space requirement

7
 ALUMINUM UPRIGHT

2.1 APPARATUS REQUIRED

• Pattern
• Liquid silicone
• A box or container to make mold housing
• Mold release

2.2 PROCEDURE

 Create an upright pattern

• Build the mold case by taking a container to hold the pattern and then pouring
silicone. Then use a plastic container to shape the mold case to perfection.
• Lay out the pattern and apply a mold release agent to the pattern to prevent it
from sticking to the mold.
• Start by adding the silicone solution to the mold case. Initially, you need to
pour the silicone solution slowly so as not to disturb the pattern. After filling
the mold case, it needs to be stored for a while to fix the silicone.
• Then remove the pattern from the mold. If the pattern is difficult to remove,
you should break the pattern so that it does not interfere with the cavity of the
mold and then remove the pattern from the mold.
• After removing the pattern, it is necessary to install the mold case and inject
molten aluminum into the mold cavity

8
  Then leave for some time to cool or solidify to get our casting

2.3 DESIGN

9
2.4 GENERAL CALCULATIONS

Volume of Upright Model: -

168.02547cm3

Mass of Aluminum needed: -

472.15g

Density of Aluminum used:-

2.7g/cm3

10
2.5 MATERIAL DETAILS

11
2.6 DETAILED DIMENSIONS OF THE MODEL

12
2.7 SOFTWARE

CFD
Computational Fluid Dynamics (CFD) is an analysis of fluid flow
using a numerical solution. You can use CFDs to analyze complex
problems, including fluid-liquid, fluid-solid, or fluid-gas
interactions. Engineering areas where CFD analysis is commonly
used include aerodynamics and fluid dynamics

WHY CFD?

CFD analysis is cheaper and faster than traditional data acquisition

testing because it has great potential to save time in the design
process. In addition, while real-world tests measure a limited
number of quantities simultaneously, CFD analysis allows you to
measure all the quantities you need at once with high spatial and
temporal resolution.

Keep in mind that CFD analysis is close to a real physical solution,

so these CFD analyzes cannot completely rule out physical test
procedures. You need to run the test for verification.

How does CFD work?

A CFD analysis basically consists of the following three phases:
● Pre-processing
In this phase the problem statement is transformed into an
idealized and discretized computer model. Assumptions are

13
 made concerning the type of flow to be modeled
(viscous/inviscid, compressible/incompressible, steady/non
steady). Other processes involved are mesh generation and
application of initial- and boundary conditions.
● Solving
The actual computations are performed by the solver, and in
this solving phase computational power is required. There are
multiple solvers available, varying in efficiency and capability
of solving certain physical phenomena.

● Post-processing
Finally, the obtained results are visualized and analyzed in the
post processing phase. At this stage the analyst can verify the
results and conclusions can be drawn based on the obtained
results. Ways of presenting the obtained results are for
example static or moving pictures, graphs or tables.

14
 CONCLUSION

3.1 RESULT

15
3.2 CONCLUSION
An aluminum upright using silicon and silica aluminum
casting was casted and tested.

16
 FUTURE SCOPE

The future scope of the study is the improvement of casting

process with more simplicity and quality using an even
cheaper and better material.

17
 REFERNCES

1. Application and use of different aluminum alloys with respect to workability, strength
and welding parameter optimization – Deekshant Varshney, Kaushal Kumar

2. Study of Mechanical Properties and Applications of Aluminum Based Composites

Manufactured Using Laser Based Additive Techniques- Sumit Choudhary & Vidit Gaur

3. Rapid casting solutions: a review- Munish Chhabra, Rupinder Singh

18