A

PROJECT REPORT
ON
FABRICATION OF STIR CASTING MACHINE
THE PROJECT REPORT SUBMITTED IN PARTIAL FULFILLMENT OF
THE REQUIREMENT OF THE DEGREE

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
SUBMITTED BY
Mr. YADNESH SUDHIR SHINDE ARMIET/ME/16 SY 234
Mr. RITESH VASUDEV SARODE ARMIET/ME/16 SR 201
Mr. GANESH SHANKAR PAWAR ARMIET/ME/16 PG 261
Mr. SALMAN SIRAJ SHAIKH ARMIET/ME/16 SS 245

UNDER THE GUIDANCE OF

Asst.Prof. HITESH PATIL

ALAMURI RATNAMALA
Institute of Engineering and Technology

Affiliated to

UNIVERSITY OF MUMBAI

Department of Mechanical Engineering

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 Academic Year: 2018-19

CERTIFICATE OF UNDERTAKING

We hereby declare that project entitled “FABRICATION OF STIR

CASTING MACHINE" Undertaken at ALAMURI RATNAMALA
INSTITUTE OF ENGINEERING AND TECHNOLOGY by

Mr. YADNESH SUDHIR SHINDE ARMIET/ME/16 SY 234

Mr. RITESH VASUDEV SARODE ARMIET/ME/16 SR 201
Mr. GANESH SHANKAR PAWAR ARMIET/ME/16 PG 261
Mr. SALMAN SIRAJ SHAIKH ARMIET/ME/16 SS 245

In partial fulfilment of B.E. MECHANICAL ENGINEERING Degree (Semester VII)

Examination, is my original work and the Project has nor formed the basis for the award of
any degree, associate ship, fellowship or any other similar titles, in Mumbai University or any
other university of India.

ASST. PROF. HITESH PATIL ASST. PROF. SAMEER GAUTAM

(PROJECT GUIDE) (PROJECT CO-ORDINATOR)

ASST. PROF. RAJESH KUMAR

(HEAD OF DEPARTMENT)
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 ACKNOWLDGEMENT

It is indeed a matter of great pleasure and privilege to be able to be able to present this
project on “FABRICATION OF STIR CASTING MACHINE.”

We are thankful to our project guide Asst.Prof. HITESH PATIL whose have given
his full effort in guiding the team in achieving the goal as well as his encouragement to
maintain our progress in track. We would like to render our sincere thanks to head of
department Asst.Prof. Rajesh Kumar (Mechanical Engineering) and staff members for their
co-operation.

I owe project success to my guide and covey my thanks to him. I would like to express
my heartfelt to all the teachers and staff members of Mechanical Engineering department of
Alamuri Ratnamala Institute of Engineering And Technology for their full support. I would
like to thank our principal Dr. L.S.Bothra for conductive environment in the institution.

I am grateful to the library staff of Alamuri Ratnamala Institute of Engineering And

Technology for the numerous books, magazines made available for handy reference a use of
internet facility.

Lastly, I am also indebted to all those who have indirectly contributed in making this
project successful.

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 TABLE OF CONTENTS

1. ACKNOWLDGEMENT iii
2. TABLE OF CONTENTS iv
3. LIST OF FIGURES v
4. LIST OF TABLES vi
5. LIST OF ABBRIVATIONS vii
6. ABSTRACT viii
7. INTRODUCTION 01
8. LITERATURE REVIEW 02
9. MAIN COMPONENTS 03
10. OBJECTIVES 10
11. PROCESS METHODOLOGY 11
12. PROBLEMS IN STIR CASTING 15
13. COST ESTIMATION 18
14. TIMEPLAN 19
15. REFERENCES 20

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 LIST OF FIGURE

FIGURE NAME PAGE

NUMBER NUMBER
3.1 BODY FRAME 3
3.2 REFRACTORY BRICKS 3
3.3 CERAMIC BLANKETS 4
3.4 POT/CONTAINER 4
3.5 HEATING WIRE 5
3.6 STIRRER 5
3.7 THERMOCOUPLE 5
3.8 AMMETER 6
3.9 VOLTMETER 7
3.10 PID CONTROLLER 7
3.11 TRANSFORMER 7
4.1 SCHEMATIC DIAGRAM OF STIR CASTING MACHINE 9
4.2 FURNACE 9
4.3 CRUCIBLE 13
4.4 FURNACE WITH CRUCIBLE 13
4.5 CRUCIBLE WITH HEATING COIL 14
4.6 STIRRER 14

v
 LIST OF TABLE

TABLE NAME PAGE

NUMBER NUMBER
6.1 COST ESTIMATION 18
7.1 TIME PLAN 19

vi
 LIST OF ABBRIVATIONS
EMF Electromotive Force
SiC Silicon Carbide
MMC Metal Matrix Composite
RPM Revolution Per Minute
AC Alternating Current
HP Horse Power
Mg Manganese
Cu Copper
Zn Zinc

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 ABSTRACT

A stir casting machine is a unique casting furnace having distinct characteristics over
others. It is mainly used in making composite in manufacturing industry . It has wide range of
application in research and development department .

The stir casting machine will use for making aluminium composite having less density
and melting point and ceramics having different density. This paper deals with design of
electronics assembly, crucible, stirrer, stirrer speed, furnace, length of heating coil. The stirrer
speed vary from 400-1000 rpm the stirrer will avoid non- wettability of particles or floating or
settling particles.

Key word:- Stir casting machine, Stirrer rod, furnace

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 CHAPTER 1
INTRODUCTION

Casting is a basic manufacturing in which a metal in solid form is taken and melted in
a furnace to its liquid form and then usually poured into a mould. The mould contains an
empty cavity of the desired shape, and then allowed to solidify. The resulting solidified part is
called as casting, which is broken out of the form to complete the process. Casting is regularly
utilized for making complex shapes that would be generally troublesome or uneconomical to
make by different strategies. Metal casters and researchers are using wide variety of furnaces
for casting purposes. For laboratory purposes, Reverberator, Hearth, or Crucible furnaces are
used. Reverberator furnaces are used to melt the metals in small quantities using a pot shaped
crucible that holds the metal over an electric heater. In electric furnaces, as electric current
flows through the material, which is a good conductor, some of the energy is dissipated in the
form of heat. This heat is generated due to the resistance offered by the material against the
flow of current. This mode of heating metals involves a good, clean and easily controllable
source of heat, which is possible to use on a very large-scale heating. The developing and
under developed countries may not allocate significant funds towards the development of
science and technology. Therefore, researchers and scientists look for alternate ways of
getting funds.Further, they put efforts to minimise the cost of the projects to the possible
extent. Balestated that for a nation to advance technologically, it must be able harness,
convert its mineral resources and fabricate most of its equipment and machines locally. In
these lines, the work presented in this paper is aimed at design and fabrication of low-cost
electrical resistance based metal melting furnace to fulfil the metal melting requirements in
the research and academic laboratories. Metals are flexible components whose fields of use
are wide in human lives.

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 CHAPTER 2
LITERATURE REVIEW

S. Balasivanandha Prabhu & G.G.Sojhamannan (2005), [1] In this study,

aluminium metal matrix composites were stir casted at different processing temperatures with
different holding times to understand the influence of process parameters on the distribution
of particle in the matrix and the resultant mechanical properties.The distribution was
examined by microstructure analysis, hardness distribution and density distribution From the
microstructure analysis, the particles were distributed uniformly in the processing temperature
750˚C and 800˚C. The particles agglomerations were
found in the processing temperature of 700˚C, 850˚C and 900˚C due to the changes of
viscosity in liquid Al matrixThe tension test revealed that ultimate strength in-creased
gradually up to 800˚C and starts to decrease gradually due to the distribution in the Al
matrix.The Ultimate strength of metal matrix composite decreases with increasing holding
time.

Manabhanjan Sahoo & Dipti Ranjan Patra (2010), [2] Taking into consideration
the effect of cost, safety, simplicity and ease of construction researchers decided to design an
electrical resistance heating furnace with indirect heating provisions.The stir casting furnace
has two main parts that enable to perform all its operations, they are: Furnace Elements and
Control Panel.This paper shows the design and fabrication of stir-casting furnace and
aluminium melted and casted to form.

Mukhtiar Ali Unar & Muhammad Jakhio (2 April 2016), [3] The research was
conducted to investigate the effect of elemental metal such as Cu-Zn-Mg in aluminum matrix
on mechanical properties of stir casting of aluminum composite materials reinforced with
alpha "Al2 O3" particles using simple foundry melting alloying and casting route. The age
hardening treatments were also applied to st : Aluminum alloy matrix can be developed
successfully with the addition of Cu-Zn-Mg metals and reinforced with "Al2O3" using stir
casting method. Results show that "Al2O3" particles up to 10% increase the tensile strength
297 MPa and elongation 17% in aluminum alloy matrix containing Cu-Zn -Mg in
aluminum.udy the aging response of the aluminum matrix on strength, ductility and hardness.

2
 CHAPTER 3

MAIN COMPONENTS

The following are the components of stir casting machine

 Body frame
 Walls
 Insulating materials
 Pot/Container
 Heating wire
 Thermocouples / Temperature sensors
 Crucible
 Stirrer
 Cover Plate
 Control Panel
 Transformer

3.1 Body Frame

The furnace body is of the dimension 46×46×46 cm3 and rises to a height of 16 cm on
four legs made of angle section mild steel bars. The frame is made with the same angle
section mild steel bars as the legs and is weld joined. The sides are made of galvanized plates
of steel and the top side is made with mild steel plate which is bolted to the frame and has a
circular opening on top.

Figure 3.1 Body frame

3
3.2 Walls
The walls are made with refractory bricks that are cut into the same shape as that of
the furnace and are joined with a paste made up of ceramic powder and glue after the gaps in
between are covered by pieces of ceramic blanket.

Fig. 3.2 Refractory bricks

3.3 Ceramic Blankets

The insulating material used in the furnace is Ceramic Blankets Ceramic blankets are
very high heat resistive material used in high temperature applications to avoid heat leakage
and fire hazards. These have very low value of thermal conductivity and highly flexible and
can be easily cut and used as insulating material. An important parameter associated with the
use of ceramic blankets is critical thickness of insulation. The critical thickness of insulation is
the minimum thickness that must be provided so that the heat loss could be minimized and for
cylindrical surfaces its value is twice that of its thermal conductivity. Ceramic blankets are
produced from exceptionally pure oxides of alumina and silica using the spinning process.

Fig. 3.3 Ceramic Blanket

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3.4 Pot/Container

The pot/container is made of the ceramic clay shaped into a cylinder of diameter 10cm
and height 15cm. The working temperature of the pot is approximately 1400oC.

Fig. 3.4 Container

3.5 Heating Wire

Heating modules are produced from the high resistance wire by coiling them and then
these coils are placed on the walls of the furnace to produce heat. A single phase 220V AC
supply is connected to the heating module. The high values of current passing through the
resistive wires convert the electrical energy into heat energy thereby serving the purpose.

5
 Fig. 3.5 Heating coil

3.6 Stirrer

The method used in fabrication of MMC requires the dispersed phase that is the
ceramic particles (SiC) to be mixed in solid state in the liquid metal. So for uniform mixing of
the ceramic particles in the liquid metal it is needed that the mixture be stirred well. So, a
stirrer is required which can withstand the high temperature and doesn’t affect the purity of
the composite. The stirrer is made of a stainless steel rod whose front end is attached with a
graphite fan. It is driven by a ½ HP AC motor and rotates at about 400 rpm. The stirrer is
inserted vertically into the crucible about one third of its height after adding the ceramic
particles. Here we have provided ways for stirring through external mediums that can be
attached to the furnace at any point through the top.

Fig. 3.6 Stirrer

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3.7 Thermocouple
Thermocouples are temperature sensing devices used to measure temperature. These
are highly effective, accurate, highly sensitive and cheaper. Here we are using a copper-
constantan thermocouple. It is required to know the temperature of the liquid metal at all
points i.e. why thermocouples are used. The thermocouple used here is the Iron-Constantan
and Chromel-Alumel (K type) whose maximum range of operation is 1200ºC.

Fig. 3.7 Thermocouple

3.8 Control Panel

The control panel has following parts

• Ammeter : An ammeter is a measuring instrument used to measure the current in

a circuit. Electric currents are measured in amperes (A), hence the name. Instruments used
to measure smaller currents, in the milliampere or microampere range, are designated
as milliammeters or microammeters.

Fig. 3.8 Ammeter

7
3.9 Voltmeter: A voltmeter is an instrument used for measuring electrical
potential difference between two points in an electric circuit. Analog voltmeters move a
pointer across a scale in proportion to the voltage of the circuit; digital voltmeters give a
numerical display of voltage by use of an analog to digital converter.

Fig 3.9 Voltmeter

3.10 PID controller: A proportional–integral–derivative controller (PID

controller or three term controller) is a control loop feedback mechanism widely used in
industrial control systems and a variety of other applications requiring continuously
modulated control.

Fig. 3.10 PID controller

8
3.11 Transformer : A transformer is a static electrical device that transfers electrical
energy between two or more circuits through electromagnetic induction. A varying current in
one coil of the transformer produces a varying magnetic field, which in turn induces a
varying electromotive force (emf) or "voltage" in a second coil.

Fig. 3.11 Transformer

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 Objectives

 To design and fabricate fully functional stir casting machine.

 Design of individual components of stir casting machine.
 Find resources for components.
 Procuring components from the respective sources.
 Starting fabrication and assembly of parts.
 Initiate the process of making metal matrix

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 CHAPTER 4

PROCESS METHODOLOGY

The first part in the construction of the furnace is the body of the furnace. To work
with highest efficiency, the furnace has to produce heat as well as retain it within the walls of
the furnace, so that the heat loss in the furnace is very less. To achieve this, the furnace needs
to be as insulated as possible while being able to withstand the thermal stresses developing
within the furnace. The construction of the body starts with building the furnace frame. The
furnace frame is made of mild steel angle sections weld joined, upon which galvanized steel
plates are also welded to form the body. Galvanization of the steel sheets adds to the
insulating property of the furnace wall which is much needed, as a result we are able to keep
the temperature of the walls at near about atmospheric temperature and avoid overheating.
But with an exception to the sides the top side of the frame is made of mild steel plate and
instead of weld shutting it we have bolted it to the frames with screws and the plate has an
opening cut in the centre which will serve to the purpose of placing the crucible inside and
removing it while operating the furnace. This top plate is not screwed to the frame until all the
things inside the furnace are completely built. In order to reduce the thermal conductivity of
the furnace after making the frame the inner sides of the frame plates are coated with an
insulating paint as well as lined with thin sheets of soft asbestos.

The use of asbestos sheets and insulating paint greatly improves heat trapping
capabilities of the furnace. After that the inner sides of the frame is lined with insulating
bricks made of refractory materials, which also acts as insulators and traps the heat lost from
the coils. Due to use of the refractory bricks which are remarkably light overall weight of the
furnace also decreases which is an advantage to the furnace and eases the furnace handling
and moving. To avail complete heat trapping and avoid heat loss through any gaps all the
gaps within the adjoining walls are covered with pieces of ceramic blankets. Then a paste is
made from ceramic powder, glue and water which acts as cement for the furnace and hence
used for closing the gaps where previously we had packed ceramic blanket pieces. The main
reason for using the paste is that ceramic powder can withstand very high temperature and at
the temperature the paste can still maintain its cohesive properties. After that the furnace is
left as it is to become dry.

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 The next part in the building is the pot and coil set-up. The pot is made up of ceramic
particles and is heated up to a temperature of 2100 C in phases. It is done so that it can get
heated up to 2100 C and still remains intact. The pot is an important part of the furnace as the
coil is wrapped around it as well as the crucible is placed inside it. The pot can be made in
various shapes and sizes and generally is made with square cross section, but here the furnace
is subjected to top loading so we have taken a pot of circular cross section. The main supply is
controlled by a selector switch. The supply is given directly through the selector switch to the
Ammeter (which gives the net amount of current flowing through the coil at a particular
instant), then the supply is provided through the energy meter which calculates the net energy
consumed in the whole circuit. The voltmeter is connected in parallel across the heating coil
(which denotes the net voltage across the coil).

Fig 4.1- Schematic diagram of Stir casting machine

Fig 4.2 Furnace

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 Fig 4.3 Crucible

Fig4.4 Furnace with crucible

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Fig 4.5 Crucible with heating coil

Fig 4.6- Stirrer

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 CHAPTER 5

PROBLEMS IN STIR CASTING

In preparing metal matrix composites by stir casting, there are several factors that need
consideration including:

 The difficulty of achieving a uniform distribution of reinforcement material.

 The poor wettability between the two main substances.
 The propensity for porosity in the cast metal matrix composite.
 Chemical reaction between reinforcement maternal and matrix alloy.

In order to achieve the optimum properties of the metal matrix composite, the distribution
of the reinforcement materials m the matrix alloy must be uniform, and the wettability of
bonding between these two substances should be optimized The chemical reaction between
reinforcement maternal and the matrix alloy and porosity must be avoided or minimised The
high Al-SiC interface bonding strength is the mam reason for the composite relatively high
specific mechanical properties A sufficient bond is achieved only when good wetting of the
reinforcement by the matrix is obtained, and this is dependent on the surface properties of the
two phases. It is believed that a strong interface permits transfer and distribution of load from
the matrix to the reinforcement, resulting m an increase in elastic modulus and strength
Fracture in discontinuously reinforced composites can result mainly from de-bonding of
particles from the matrix.

5.1 Particle Distribution

The distribution of the particle reinforcement in the matrix alloy is significantly
influence by three main stages the melt stage, solidification and post-solidification process
Melt and solidification stages are inter-related and need to be continuously controlled Post-
solidification process could help to homogenize the distribution of the particles in the final
product Particle distribution in the matrix material during the melt stage of the casting process
mainly depends on the viscosity of the slurry, the extent to which particles are successfully
incorporated in the melt, and the characteristics of the reinforcement particles The
characteristics of the reinforcement particles influence settling rate, and theeffectiveness of

15
mixing in breaking up agglomerates, minimising gas entrapment and attaining distribution of
the particles.

5.2 Particle Characteristics

One major processing problem is that particles either sink or float, depending on the
particle-to-liquid density ratio In foundry operations, segregation of the particles may occur
between the time stirring has stopped, and the melt has solidified Clustering of the particles is
a contnbutory problem, making the particles settle more quickly Therefore, the particles may
be unevenly distributed macroscopically (denuded region due to settling) and microscopically
(clusters of particles) Particle enriched zones may form either as a consequence of gravity
segregation of particles in melts during holding, or during slow solidification or as a
consequence of selective segregation under the action of centrifugal acceleration in
centrifugal casting. In foundry operations, where composite ingots are re-melted for product
casting, there may be problems of clustering if the melt is not intensively stirred. At
sufficiently long holding times, top parts of the casting are completely denuded of particles,
which settle to the lower parts of the casting, as a function of time Therefore the melt must be
re-stirred prior to casting if long holding times the molten state are used.

5.3 Mixing
It is essential to produce as uniform a distribution as possible without any gas
entrapment, since any gas bubbles will attach to reinforcement particles leading to poor
bonding with the matrix Excessive gases content can result from over agitated melts, which
lead to unacceptable porosity content in the ingot Even in inert gas or vacuum operated
processes, top melt surface agitation is known to cause problem. Stirring is a complex
phenomenon, and it can be a problem to control the process such that a uniform distribution
of particles is achieved Mechanical stirring being usually used during melt preparation or
holding, the stirring condition, melt temperature, and the type, amount and nature of the
particles are some of the mam factors to consider when investigating this phenomenon.

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5.4 Solidification
There are essentially three mechanisms, which will affect particle redistribution during
solidification processing These are agglomeration, sedimentation and particle engulfment or
rejection (pushing) ahead of the solidification front The prevalence of one or more of these
mechanisms is dependent upon elements of the processing technique as well as the physical
and chemical properties of the particle and the matrix. The distribution of particles in the
resulting solid may or may not follow the distribution in the liquid The actual distribution of
particles that one obtains in the solidified material will largely depend upon the morphology
of the interface that is present under given experimental conditions When the particles are
trapped by a plane front or cells, the distribution remains similar to that present in the liquid
prior to solidification On the other hand, when a dendritic structure is present during
solidification.

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 CHAPTER 6

COST ESTIMATION

Table 6.1- Cost Estimation

Sr. No. COMPONENT ESTIMATED COST (Rs)

1 Refractory Bricks 35rs per piece
2 Ceramic Powder 85rs per piece
3 Ceramic Blanket 760rs per roll
4 Metal Bars/ Strips/ Sheets 20rs per Kg
5 AC Motor 3000-5000rs
6 AC Motor Speed controller 600-1000rs
7 Thermocouple 500-700rs
8 Aluminum ingots 150rs per Kg
9 Sic Powder 1280rs per Kg
10 Crucible 1300rs
11 Heating Coil 900rs

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 CHAPTER 7

TIME PLAN

Table 7.1: Time Plan

Work Done/ August September October November December January

to be Done

Topic
Selection
Literature
Review
Design of
Components
Methodology
Study
Cost
Estimation
Finding
Sources of
Project
Components
Procuring
the
Components

Assembly
and
Fabrication
of project

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 REFERENCES

1. S. Balasivanandha Prabhu & G.G.Sojhamannan (2005), [1]. “: Effect of

Processing Parameters on Metal Matrix Composites: Stir Casting Process ”
2. Manabhanjan Sahoo &Dipti Ranjan Patra (2010), [2] “Design and Fabrication of a
Stir Casting Furnace Set-up”
3. Mukhtiar Ali Unar &Muhammad Jakhi (Mehran University of Engineering
and Technology, Jamshoro,Pakistan) “Manufacturing of Aluminum
Composite Material Using Stir Casting Process ”

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