BHARATHIYAR COLLEGE OF ENGINEERING & TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING FINAL YEAR

PROJECT TITLE Design, Manufacturing and Testing of controlled Stir Casting Furnace

PROJECT MEMBERS
MANIVANNAN.N FRANCIS.T MOHAMAD ASHIK.M GIPSON PEREIRA

PROJECT GUIDE
Mr.GUNABALAN

ABSTRACT
Design and manufacture a Stir casting furnace for non ferrus alloys casting
Design and selection of Heating system Crucible selection Design of stirring system Thermocouple for Temperature control Environmental control system design

Testing the performance of the furnace

INTRODUCTION
Stir casting can be used to synthesis both magnesium alloys and their composites. In the case of composites, the reinforcing phase is incorporated into a molten metallic matrix using various proprietary techniques. Magnesium, with a specific gravity of only 1.74, is the lowest-density metal available for engineering use. It is produced either by electrolytic reduction of MgCl2 or by chemical reduction of MgO by Si in the form of ferrosilicon.

STIR CASTING It is a liquid state method of composite materials fabrication, in which a dispersed phase (ceramic particles, short fibers)is mixed with a molten matrix metal by means of mechanical stirring. Stir Casting is the simplest and the most cost effective method of liquid state fabrication. The liquid composite material is then cast by conventional casting methods and may also be processed by conventional Metal Forming Technology. Stir Casting is characterized by the following features: Content of dispersed phase is limited (usually not more than 30 vol.%).

Distribution of dispersed phase throughout the matrix is not perfectly homogeneous: 1. There are local clouds (clusters) of the dispersed particles (fibers) 2. There may be gravity segregation of the dispersed phase due to a difference in the densities of the dispersed and matrix phase. The technology is relatively simple and low cost. Distribution of dispersed phase may be improved if the matrix is in semi-solid condition. The method using stirring metal composite materials in semisolid state is called Rheocasting. High viscosity of the semi-solid matrix material enables better mixing of the dispersed phase.

Experimental Setup of Stir Casting

Mechanical Stirrer Designs

PROCESS PLANNING
Material selection for the Casting process. Design, 2D drafting and 3D modeling using CAD software's Analyzing Production according to the desired drawing Assembling the finished product

CONCLUSION
1. Higher blade angles and lower viscosity result in reduced particulate dispersion time. 2. A minimum stirring speed of 100 rpm for water is required for uniform dispersion to occur.

LITERATURE SURVEY M. Jayamathi, S. Seshan, S. V. Kailas, K. Kumar and T. S. Srivatsan, Influence of Reinforcement on Microstructure and Mechanical Response of a Magnesium Alloy, Cur-rent Science, Vol. 87, No. 9, 2004, pp. 1218-1231.
V. K. Lindroos and M. J. Talvitie, Recent Advances in Metal Matrix Composites, Journal of Material Process-ing Technology, Vol. 53, 1995, pp. 273-284. David Roylance, Department of Materials Science and

REFERENCES

Engineering, Massachusetts Institute of Technology

,Cambridge, MA 02139

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