DESIGN AND FABRICATION OF A QUENCH TANK

Transcription

1 DESIGN AND FABRICATION OF A QUENCH TANK BY SHOBOWALE JOSHUA OLUWADAMILARE 2004/19023EM IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD OF BACHELOR OF ENRINGGERING DEGREE IN MECHANICAL ENGINEERING, FEDERAL UNIVERSITY OF TECHNOLOGY, MINNA, NIGER STATE NIGERIA January, 2010 ii

2 DECLARATION I Joshua Oluwadamilare Shobowale declare that this project work titled "Design and Fabrication of a Quench Tank" was carried out by me under the supervision ofengr J.B. Agboola, in the Department of Mechanical Engineering, Federal University of Technology, Minna, Niger state and it has not been submitted in part or whole in any other university or higher institution for any degree or diploma programme, all literature reviews and excerpts from other sources were properly referenced. ~huao. Date Student III

3 CERTIFICATION This is to certify that this project titled: "Design and Fabrication of a Quench Tank" was carried out by Shobowale Joshua ( EM) under the supervision of Engr J.B. Agboola. In the Department of Mechanical Engineering, Federal University of Technology, Minna, in partial fulfillment of the award of Bachelor of Engineering (B.Eng) Degree in Mechanical Engineering. Engr J.B. Agboola Date Supervisor Prof R.H. Khan Date Head of Department External Examiner IV

4 DEDICATION' To the King Eternal, Immortal, Invisible, Invincible, All Mighty, All Wise, Almighty, My God and My Father, whose emissary I am, to the Son the Lord, My Lord Jesus Christ and the Lovely Holy Spirit is this worthy delectation. v

5 ACKNOWLEDGMENT All thanks, praise, glory and adoration be to the Almighty God, The Lord Jesus and the Holy Spirit so real to me for Love, comfort, support and grace that has made me what I am today, lowe everything to Gods help. I am thankful to the Godhead for how far I have come with His help I say Lord I thank you. Firstly I will very sincerely appreciate my wonderful supcrvisor Engr J.B. Agboola for his support, correction, help and assistance in the execution of this project I will say Sir that your were more than a supervisor you were a father and I say may God bless you mightily. And to our gracious, understanding and caring Head of Department whose coming in again as HOD has made many's hope of graduating rekindled again because of his good heart you are wonderful sir. Also, I specially acknowledge Engr (Dr) O.K. Abubakre who is a very dynamic and wonderful man who taught us to be a man and helped us greatly in the department I say your children will not suffer sir. And to every other lecturer in the department who have contributed gre.atly in making me realize my dream of becoming an engineer; my good Level Adviser Engr Muriana, Exam Officer Engr Salawu, and Engr Onouha, Engr IK, Engr Vincent 0., Engr Ndaliman, Engr Joshua. F., Engr. E.P. Egbe, and Engr Femi O. in absentia, My God will reward your effort. To the most wonderful people in my life without whose companionship I will not be able to realize my dream and aim they have contributed greatly to my being here today. Firstly to my wonderfull father and My Man of God, Elder Benjamin Olufemi Shobowale whose tutelage, love and care has made me know God and find the path that I am now treading and is leading me to greatness, Daddy, I love you dearly. And to my wonderful, lovely and caring mummy you are the best mum in the world your care, love and support have made me great, your prayers, and remembrance are always with me. To my wonderfull sister Mrs G.O. Owoyemi you are a rare gem, your endurance and patience inspires me may God remember you for Good. To my inspirational Pastor and brother Pastor (Engr) Sunday Shobowale whose gentle spirit has motivated me towards the same your contribution and support will not go unrewarded Sir. And now a very great person, most sought after and dynamic personality, the man with vision and mission unabortable, Engr Jonathan Shobowale, who graciously and willingly supported me in every respect during the process of my schooling. I say May God bless you and grant your earnest desires and your desires will come to pass very shortly. And VI

6 to your wonderull and caring wife Mrs Debby Shobowale who served to me as mother very loving and caring, May God bless you mightily. Pastor Emmanuel Shobowale may God bless you real good and take you to a very high height in life and ministry and your wife in Jesus name. And to my lovely little sister (ahaha!!) Comfort Moyinoluwa Shobowale I love you and may God see to the realization of your great desire. And to my nephews Ayobami, Joshua, Tosin and bright Aramide I love you all really, you are an inspiration to me. To the most wonderfull set of people on FUT Campus the World Changers (WCF) with whom my destiny has opened up. The 2008/2009 executives, you enable me to realize me God bless you. And to my Pals in the Department, Philip Okpe, Timothy Adeneye, Sunday F., Rex, Thompson (Class rep). I'll miss y'all. vii

7 ABSTRACT This project is centered around the design and fabrication of a quench tank. The constructed tank is used for quenching of metals after austenitizing i.e raising to temperature of about C in a furnace. The various parameter that were considered during the construction of the quench tank are (i) Maintaining the temperature of the quenchant between prescribed limits, this was achieved by the adoption of circulation by the aid of a pumping machine. This system ensures that the heat given out by quenching is circulated and transmitted. (ii) Agitation of the quenchant, the tank was designed such that a quench arena was provided so that when the metal is dropped in it will be agitated by the flow of the liquid over it thereby preventing formation of bubbles over the metal to be quenched by the flushing produced by the pump (iii) Effective cooling of the quenchant (iv) size of the metal to be quenched. The quench tank is made to carry any liquid quenchant of about 28.3 litres. The height of the quench tank is 400mm with a diameter of about 300mm and the quench arena is about 7 litres and the capacity of the pump is 0.5 watt with a maximum flow rate of 40llmin which is just needed to produce the needed power for effective circulation. The quench tank can take various quenchant such as Brine, water and oil depending on the material to be quenched and the desired result. Vlll

8 TABLE OF CONTENTS Cover page Title page Declaration Certification - Dedication Acknowledgment Abstract Table of contents 11 iii IV V vi viii IX CHAPTER ONE 1.0 Introduction 1.1 Background of Project 1.2 Aims and Objectives 1.3 Justification of Project 1.4 Methodology Quench Tank Construction 1.5 Scope and Limitation of Project Importance of Quench Tank CHAPTER TWO LITERATURE REVIEW 2.0 Heat Treatment 2.1 Types of Heat Treatment Annealing Hardening and Tempering (Quenching And Tempering) Precipitation Hardening ix

9 2.1.4 Selective Hardening Quenching Of Steels Liquid Quenching Fundamentals of Quenching and Quenchant Evaluation Factors that Affect the Quenching of Metals J Effect of Cooling Rate on Structure and Hardness of Quenched Steel Various Quench Tanks QED Quench Tank QTS 124 Small Portable Agitated Quench Tank Electrically-Heated Quench Tank Cures Products Post Heat-Treatment 23 CHAPTER THREE 3.0 Design Analysis and Calculation Design Analysis Design Proportion Structural Design Design Calculation Volume of Tank Flow Rate of Quench Tank Circulation of Quenchant Strength of the Structure Quench Arena IWorkpiece 30 CHAPTER FOUR: MATERIALS SELECTION, COST ANALYSIS, TESTING AND RESULT 4.1 Material Selection- 4.2 Structural Assembly x

10 4.3 Fabrication Procedure Marking Out Cutting Welding Assembling Cleaning Of Parts Painting Cost Analysis Material Cost Labour cost Overhead Cost Total Cost 4.6 Testing 4.7 Result 4.8 Safety Rules For Operation 4.9 Maintenance CHAPTER FIVE: CONCLUSION AND RECOMMENDATION 5.1 Conclusion 5.2 Recommendations References Xl