vii TABLE OF CONTENTS CHAPTER TITLE PAGE DECLARATION DEDICATION ACKNOWLEDGEMENT ABSTRACT ABSTRAK

Transcription

1 vii TABLE OF CONTENTS CHAPTER TITLE PAGE DECLARATION DEDICATION ACKNOWLEDGEMENT ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF ABBREVIATIONS LIST OF SYMBOLS LIST OF APPENDICES ii iii iv v vi x xi xiii xiv xv xvi 1 INTRODUCTION Project Background Study Motivations Study Objectives Scope of Work Significance of Findings Dissertation Organization 3 2 LITERATURE REVIEW Introduction Strategy of Experimentation Process Quality in Manufacturing Techniques for Process Quality Improvement Pareto Diagram Cause and Effect Diagram Check Sheet Process Flow Diagram 11

2 viii Scatter Diagram Histogram Control Chart Design of Experiments Design of Experiment Process Basic Principle of DOE Types of DOE Taguchi Method Classical Factorial Design Response Surface Methodology Classical Design V.S. Taguchi Full Factorial Design Two-level Factorial Design Three-level Factorial Design Mixed-level Factorials Fractional Factorial Design Aluminum Aluminum alloy casting Aluminum silicon LM6 alloys Solidification of Al-Si Alloys Lost Foam Casting Process History of Lost Foam Casting Advantages of Lost Foam Casting Cause-Effect Diagram to Produce Sound LFC Significant Parameters affecting LFC Vibration time Sand size Slurry viscosity Pouring temperature Related Works Chapter Summary 35 3 RESEARCH METHODOLOGY Determine Problem of statement Determine objective of the study Selection of Factors and Levels Selection of Response Variable Lost Foam Casting Process Pattern Making 42

3 ix Coating Sand filling and vibration, compaction Pouring Mechanism Sample Analysis Design of Experiment Software Result Analysis Chapter Summery 46 4 EXPERIMENTAL WORK Introduction LFC Experimental Steps Preparation of Polystyrene beads Pattern making Coating and dry Sand filling, Vibration and Compaction Temperature Measurement Melting procedure and casting Factorial Design of Experiment Stpes Input Data Selecting Independent Factors Selection of Response Variable Specify Names and Levels for Factors Identify Control and Noise Factors Identifying potential interactions choosing experimental design Runing the Experiment Data Analysis Prepare the ANOVA table Construct the normal probability plot Construct the main effect Interaction plots Construct the Residual versus Fitted Values and Normal Probability Plot of the Residual Chapter Summery 60 5 RESULT AND DISCUSSION Analysis of the Results ANOVA Analyses for 3mm Thickness 61

4 x ANOVA for Silicon Spacing ANOVA for Surface Roughness ANOVA for Porosity Normal Probability Plot Normal Probability Plot for Silicon Spacing Normal Probability Plot for Surface Roughness Normal Probability Plot for Porosity Interaction Effect Interaction Effect for Silicon Spacing Interaction Effect for Surface Roughness Interaction Effect for Porosity Residual Plot Residual Analysis for Silicon Spacing Residual Analysis for Surface Roughness Residual Analysis for Porosity Chapter Summary 75 6 CONCLUSION Conclusion Future Work 77 REFERENCES 79 A.1 Residual analysis for silicon spacing 82 Appendices A B 82 89

5 xi LIST OF TABLES TABLE NO. TITLE PAGE 2.1 General Characteristics of Aluminium Related works Related works Related works Parameter Factors and Levels Actuall layout of Design for 3mm Thickness ANOVA for silicon spacing ANOVA for surface roughness ANOVA for porostiy 65 A.1 Actuall layout of design for 3mm thickness 82 A.2 ANOVA for silicon spacing 83 A.3 ANOVA for surface roughness 83 A.4 ANOVA for porosity 83

6 xii LIST OF FIGURES FIGURE NO. TITLE PAGE 2.1 Pareto chart Cause and effect diagram Check sheet Process flow diagram Scatter diagram Histogram Control Chart Lost-foam Casting Process General project methodology Lost-foam casting process Pattern size Sample analysis procedure Polystyrene beads Pattern dimensions in 3-D Prepared foams Coating and drying process Positon of polystyrenenpattern in the flask Sand filling, vibration and compaction process Induction furnace used for melting Pouring casting procedure Normal probability plot for silicon spacing Normal probability plot for surface roughness Normal probability plot for porosity Effect of sand size and slurry on silicon spacing Effect of slurry and sand size on silicon spacing Effect of BD in 3D on silicon spacing Effect of slurry and sand size 70

7 xiii 5.8 Effect of slurry and vibration time Effect of vibration time and sand size Residual V. predicted for silicon spacing Normal probability of residual for silicon spacing Residual V. predicted for surface roughness Normal probability of residual for surface roughness Residual V. predicted for porosity Normal probability of residual for porosity 74 A.1 Normal probability plot for Silicon Spacing 84 A.2 Normal probability plot for surface roughness 84 A.3 Normal probability plot for porosity 85 A.4 Effect of Slurry and Sand size on Silicon Spacing 85 A.5 Effect of Slurry and Sand size on Silicon Spacing 86 A.6 Effect of BD in 3D on Silicon Spacing 86 A.7 Effect of BD in 3D on Silicon Spacing 87 A.8 Residual V. predicted for for silicon spacing 87 A.9 Normal probability of residual for silicon spacing 88 B.1 residual V. predicted for surface soughnes 89 B.2 Normal probability of residual for surface roughness 90 B.3 Residual V. predicted for porosity 90 B.4 Normal probability of residual for porosity 91 B.5 Effect of Vibration time and Sand Size 91 B.6 Effect of Vibration time and Sand Size 92 B.7 Effect of Vibration time and Sand Size 92 B.8 Effect of Vibration time and Sand Size 93 B.9 Effect of Vibration time and Sand Size 93 B.10 Normal probability plot for surface roughness 94 B.11 Effect of Vibration time and Sand Size 94 B.12 Effect of Slurry and Sand Size 95 B.13 Effect of Slurry and Vibration Time 95

8 xiv LIST OF ABBREVIATIONS LFC - Lost Foam Casting EPS - expandable polystyrene DOE - Design Of Experiment ANOVA - Analysis Of Variance GFN - Grain Fineness Number RSM - Response Surface Methodology PMMA - Polymethyl Methacrylate CTE - Coefficient of Thermal Expansion FMEA - Failure mode and Effect Analysis DTA - Differentially Thermal Analysis QFD - Quality Function Deployment SPC - Statistical Process Control

9 xv LIST OF SYMBOLS Al - Wavelength Fe - Iron Cu - Copper Mg - Magnesium Ni - Nicel Zn - Zinc PAC - Polyalkylene carbonate Si - Silicon -

10 xvi LIST OF APPENDICES APPENDIX TITLE PAGE A RESULT ANALYSIS FOR 24MM THICKNESS 82 B INTERACTION PLOTS FOR 24MM THICKNESS 89