Sand Muller Report 2015 Amk 491t6w

DESIGN AND FABRICATION OF SAND MULLER Submitted in the partial fulfillment of the requirement for the award

“DIPLOMA

IN MECHANICAL ENGINEERING (FOUNDRY)”

SUBMITTED BY:

1. P.JAYACHANDRU 2. C.VIGNESH 5.R.PRITHIVIRAJAN 3. K.SURENDHAR

4. S.HARI

Under guidance of Mr V.K.RAJENDRAN, M.E. OCTOBER 2015 DEPARTMENT OF MECHANICAL ENGINEERING (FOUNDRY). A.M.K TECHNOLOGICAL POLYTECHNIC COLLEGE CHENNAI 600123

A.M.K TECHNOLOGICAL POLYTECHNIC COLLEGE CHENNAI- BANGALORE ROAD SEMBARAMBAKKAM CHENNAI 600123

BONAFIDE CERTIFICATE This is to certify that this Project work on “DESIGN AND FABRICATION OF SAND MULLER ”

submitted by …………………… ……………. Reg. No. …………… in partial fulfillment for the award of DIPLOMA IN MECHANICAL ENGINEERING (FOUNDRY) This is the bonafide record of work carried out by him under our supervision during the year 2015

Submitted for the Viva-voce exam held on ……………..

H.O.D

INTERNAL EXAMINER

PROJECT GUIDE

EXTERNAL EXAMINER

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT

At the outset, we would like to emphasize our sincere thanks to the Principal Mr. A.VIJAY KISHORE,M.TECH for encouragement and valuable advice.

We thank our Esquired Head of Department Mr. S.N. SUNDAR, M..E. for presenting his filiations on us. We are grateful on our Entourages Mr. V.K.RAJENDRAN, M.E. For guiding in various aspects of the project making it a grand success. We also owe our sincere thanks to all staff of the Mechanical Department and Foundry Department.

Ultimately, we extend our thanks to all who had rendered their cooperation for the success of the project.

CONTENTS

CONTENTS

 SYNOPSIS  INTRODUCTION  NECESSITY  CONSTRUCTION  WORKING PRINCIPLE  COMPARISON  SPECIFICATION  PAINTING & FINISHING  DRAWINGS  FEATURES OF SAND MULLER  COST ESTIMATION  CONCLUSION  BIBLIOGRAPHY

SYNOPSIS

SYNOPSIS

In our project fabrication of sand mixing Muller. The mixing and conditioning of sand is done automatically by the sand Muller. In early days in industries are using manual method so to reduce the time and money. We have to make the sand Muller. In this Muller, metal wheels rotating at slow speed over the tempered moulding sand mixture. The sand, moisture, additives, binded is mixed thoroughly and uniformly. The cost of preparing the moulding sand by using Muller is economically cheap. The time taken for conditioning of sand is less than that when we use manual or old method. Ater mixing the sand it may be taken out from a drop door at the bottom of the Muller.

INTRODUCTION

INTRODUCTION

The recent innovation in the development of the foundry industry compels the use of sand mixing muller in the place of manual equipment such as shovel etc. If significantly reduces the man power and mixing time. The sand mixing muller eliminates any use of manual equipment for Co 2Silicate and mixing. The sand mixing muller does not read only manual sacrifice for mixing the sand. Now-a-days almost all the foundries in our country are involved in mass production and they have achieved that with the aid of sand mixing muller as part of their plant mechanization.

NECESSITY

NECESSITY

SAND MIXING MULLER "The Foundry Sand Muller is a specialized production machine and a foundry men judges the muller by sand its produce". Many million of varied particles must be uniformly intermingled and surface coated with viscous bond consisting of bentonite plus water. "Water and bond must be kneaded into a dough-like consistency with development of adhesive glue properties. So that the glue can readily encom the sand grains". As mulling produces, the mixture becomes more uniform with the respect to physical and mechanical properties. In most foundries extent of mulling is established on an arbitrary time or mulling energy basis, as a function of sand capacity demand. The mulling process "should loose complete disorder so that mulled product is uniform throughout when it sampled and tested". Probability Laws tells that some sand grains will not be moved at all in the mulling action, while a like number be moved continuously. In other word, "movement is strictly random".

CONSTRUCTION

CONSTRUCTION

The equipment is made up of 3 mm thick mild steel sheet metal. The equipment is consists of stationary cylindrical steel shell of small capacity. The mouth is provided at the side of the cylindrical steel shell. The opening and closing of mouth is done with provision of shutter door. The mouth controls the uniform flow of sand, after the mixing. The cylindrical steel shell is mounted from the base with the help of four legs provided on the four corner of cylindrical shell. An electric motor is provided at the base of the equipment. The motor shaft is connecting with the plunge. The bearing plates are ed by 4 number of welded pillars.

WORKING PRINCIPLE

WORKING PRINCIPLE

The principle of working of sand mixing muller is that the two rotating wheel, rotates above the mounted axis for uniform mixing of sand particles present inside the steel shell. The principle of mulling is performed for both Co2 and green sand molding process. The primitive ingredients namely, 1. Molding Sand. 2. Saw Dust. 3. Bentonite Powder 4. Required Moisture. are filled inside the steel shell. The muller is switched on so that the rotatary motion is transferred from the motor to the motor shaft through the reduction gear box. As a result the two rotating whell starts rotation in the clock-wise direction of the speed of 900 rpm due to this rotating effect, the sand particles runs through the steel shell freely. As the particles run through the added ingredients mixes with one another finely. Due to the speed rotating of wheel there is a chance for the molding sand to stack over the centre of the assembly to prevent this two sharp edged blade are provided. This is performed for about 15 minutes or up to the uniform mixing of sand which is earlier. Finally the shutter door provided is opened and the sand is collected through the mouth in the sand collector.

COMPARISION OF SAND MULLER BETWEEN HAND MULLING

COMPARISION OF SAND MULLER BETWEEN HAND MULLING

SL.NO. 1. 2. 3.

SAND MULLER Higher Production Rate Continuous Production Requirement Manual Power is

HAND MULLING Low Production Rate Not as Sand Muller Requirement of Manual

4. 5.

less Cost of Production is less Uniformly sand mixing

6.

guaranteed as sand muller. Quality of sand produced remain Quality depends upon the

1. 2.

same for ever process. worker LIMITATION Intial cost is high No initial cost is needed It requires electric or any power No such thing is needed.

3.

sources Conveying of sand is difficult

power is high Cost of Production is high is Uniformly sand mixing is not

Process can be carried out at work place

SPECIFICATION

SPECIFICATION

Over all Height of Muller -

900 mm

CYLINDRICAL SHELL Diameter

-

600 mm

Height

-

600 mm

Thickness

-

3 mm

Base Thickness

-

5 mm

ROTATING WHEELS Diameter

-

30 mm

Length

-

30 mm

Rpm -

900

MOTOR Rpm -

1800

Phase

-

H.P. -

0.25

BASE

Single Phase

Height

-

350 mm

ADVANTAGES

ADVANTAGES

 It requires simple maintenance cares.

 . Thus this project does not require any cooling arrangements.

 USED as a re production system for foundry sand.

 Checking and cleaning are easy because of the main parts are screwed

 Easy to Handle.

DISADVANTAGES

DISADVANTAGES

Initial cost is high Electric power Required Noise In Operation High maintenance cost

APPLICATION

APPLICATIONS

It is very much useful for foundry plant.

It is used to recondition the sand

for making moulding sand.

FEATURES OF THIS PROJECT

 It can installed easily  LOW electrical power consumption  It can be utilized  It is simple in construction  Low cost  Less weight and easy to handle  Life of system increased  It is simple in operation..

PAINTING AND FINISHING

PAINTING AND FINISHING

JOB PREPARATION: Before welding, remove any bend in the L angle with the sludge hammer on the anvil block. Then it is cut to the required length with the hacksaw blade and fabricated to required dimensional shape with are welding. FINISHING OPERATION BEFORE PAINTING: After welding, any slag on the welded area is removed with the chipping hammer and cleaned with the metal wire brush. Then all the surfaces are rubbed with the emery sheet. Metal primer is applied on the surfaces with the brush. After drying the metal primer, the second coating is applied with the paint.

DRAWING

FEATURES OF SAND MULLER

FEATURES OF SAND MULLER

 It is compact in size  It can be move  The electrical power consumption is very low

 It can be utilized at our work shop  It is simple in construction  Low cost.  Less weight and easy to handle  It reduces the man power  It is used in mass production

COST ESTIMATION

COST ESTIM ATION

1.

Electric Motor 1/4th HP

---------------------------------

2600.00

2.

Rotating whell and sand guide -------------------------

500.00

3.

Muller Stand ------------------------------------------------

500.00

4.

Muller drum -------------------------------------------------

1800.00

5.

Painting and finishing ------------------------------------

200.00

6.

Transportation Charges ---------------------------------

200.00

7.

Miscellanies charges --------------------------------------

100.00 -----------5900.00

CONCLUSION

CONCLUSION This project gives all the necessary experience that "which one resembles as a simple shape, provides a great work under production". This project cannot be finished by simply buying the products as available in the outside market. As we it self carried out all the work involved in the production ofthis project, expect fabrication work. We experienced the actual difficulties in the production.

We once more thankful to our honourable industrial superiors, professors and friends those helped mostly for our successful completion of this project and also thankful to our honourable principal who gave permission for the use of materials in the college for our project work.

BIBLIOGRAPHY

BIBLIOGRAPHY

1. MANUFACTURING PROCESS BY S.S.MANIAN 2. PRODUCTION TECHNOLOGY BY JAIN

3. MACHINE SHOP TECHNOLOGY BY S.S.MANIAN

4. WORKSHOP TECHNOLOGY BY HAJRA CHOUDRY 5. A TEXT BOOK OF FOUNDRY TECHNOLOGY - O.P. KHANNA

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