A COMPUTER- AIDED DESIGN (CAD) OF SAND CASTING OPERATIONS

Abstract

The development of Computer- Aided Design (CAD) model and programs to be used in sand casting operations was carried out in this project. The model incorporates standard shape changes which are required to effect feeding as a result of thermal contraction and solidification during the casting process. It also incorporates the cost of the sand casting product designed in this project (boss and flange) which can also be used for any other sand casting products. A suitable CAD software program was developed using Visual Basic Language. The program generates automatically drawings of parts to be cast (CADD) for boss and flange in 2D and 3D; and also parts to be cast in position in the moulding box ready for pouring for both flange and boss in 2D exploded view from a feature based development. The Visual Basic program and model are developed to generate automatically necessary parameters needed to cast a non-defective casting for example: the volume of the mould; volume or sand; volume of mould cavity; volume of molten metal needed; pouring time; thermal contraction; yield or casting; solidification feeding efficiency; time; practical machining allowance; value of linear shrinkage; total weight; and conductive heat now. Three types or materials were used to achieve different results (Aluminium, Cast Iron, and Brass) for flange and boss, making six samples in all- 3 samples for boss and 3 samples for flange. The computer program and model for costing called Computer-Aided (CAC) of sand casting products were developed. Costing Three types of materials were used to test the models and resulting softwares. The CAD, CADD, Manufacturing 99.9% correlation, programs developed emphasizing are reliable that and CAC results obtained have an average of the models and the Computer-Aided casting products; aided by its costing implications Integrated and can be used in producing a good and sound sand that use different types or materials.