Design and develop mold for EM 8 standard test method for tension testing of metallic material

Ishak, Muhammad Syahir (2021) Design and develop mold for EM 8 standard test method for tension testing of metallic material. Project Report. Melaka, Malaysia, Universiti Teknikal Malaysia Melaka. (Submitted)

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Abstract

There are two types of casting processes, expendable mold and permanent mold. The purpose of this research is to make a permanent mold out of a metallic material. There are a few mold designs that can be compared between the old mold and the new mould design. Casting is an excellent method for mass production, and the design can include a variable number of cavities. The drawing is made with a solidwork programmed, and the design chosen must meet the improvement criteria. During the manufacturing process, a 3-axis conventional milling machine is used to machine the mold cavity to obtain squaring stock and datum side. Surface grinding machines are used to achieve flatness in order to prevent pouring leaks and for assembly. A solidwork design is exported to CATIA v5 in order to generate NC code and machining simulations. The cavity pattern is created using a 5 axis CNC milling machine. The cutting tool is the most important to obtain a precise design in order to avoid any defects in the mold pattern, which can affect the quality of the product while making it easier to assemble. Then, in order to achieve the goal, a casting process is used to perform testing. The material of the product is aluminium A356, which is appropriate for this study. In this study, a parameter important for avoiding product defects was investigated, such as a solidified, pouring speed, pre heated mold, and so on. To complete this study, the product's surface is evaluated using a surface roughness tester to obtain data. Based on this information, a t – test is run using Minitab software to compare the CNC method to direct casting. The graph will be generated by software, and evidence will be provided to support the probability expectation.

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