FACULTY OF MECHANICAL ENGINEERING, UNIVERSITI TECHNOLOGI MARA (UITM) LABORATORY REPORT

Program

Bachelor of Mechanical Engineering (Hons) Manufacturing (EM221) Bachelor of Engineering (Hons) Mechanical (EM220)

Course Course Code Laboratory Name Lecturer Name Title of Experiment Group

: : : : : :

Manufacturing Processes Laboratory MEM564 FOUNDRY MOHD. RIDHWAN MOHAMMED REDZA SAND TESTING PREPARATION (GFN) EMD5M 3A

No. Student Name 1. MUHAMMAD YUSRY BIN YUSUF 2. 3. 4. 5. NOR AKRAM BIN CHE MOHD NOR NUR KHALIDAH BINTI MOHAMED

Student ID Number 2012510627 2012192645 2012766163

Signature

Date of Practical Session

Staff Certification (Signature)

Date of Report Submission

Staff Certification (Signature)

KUMPULAN

29

LABORATORY REPORT CONTENTS General Guidelines: LEVEL Lemah Sederhana Memuaskan (Weak) (Marginal) (Satisfactory) 1,2 3,4 5,6 Scale Page No: FRONT COVER GRADING FORM CONTENTS Page 1 ___ x 1 10 ___ x 4 10 ___ x 10 10 ___ x 7 10 ___ x 3 10 ___ x 15 10 ___ x 17 10 ___ x 17 10 ___ x 6 10 ___ x 5 10 ___ x 10 10 ___ x 5 10
1

Baik (Good) 7,8

Cemerlang (Excellent) 9,10 CO Achievem ent Remarks

Marks Allocated

Marks Obtained

1.0 Title

Page 2 Page 2

CO1 (Total Marks:40)

2.0 Objective(s)

3.0 Introduction (background Page 2 and theory) Page 2 4.0 Apparatus Page 3 4. 1 Industrial Apparatus

5.0 Experimental Procedure

Page 3 Page 3

6.0 Results & Data Analysis Page 4 7.0 Discussion of Results Page 5 8.0 Conclusion Page 5 9.0 Recommendation Page 5 10.0 References

CO4 (Total Marks:60)

11.0 Overall Report

1.0 TITLE SAND TESTING PREPARATION (GFN) 2.0 OBJECTIVE To find out the sand grain size and calculates the Grain Fineness Number (GFN). 3.0 INTRODUCTION A system has been developed to rapidly express the average grain size of a given sand sample. The Grain Fineness Number (GFN) is the quantitative indication of the grain distribution of the sand sample by carrying out a sand sieve analysis. The calculated formula can be derived as

Typical Sand Size: Coarse GFN 40-100 Fine GFN 100-220 Ferrous Cast Typically GFN 70 GFN < 50 too coarse poor surface quality in casting GFN >100 too fine low permeability, large surface area 4.0 APPARATUS

SIEVE SHAKER

DIGITAL SCALE BALANCE

MATERIALS: Silica Sand. EQUIPMENT: 1 set of 9 sieves (53,75,106,150,212,300,425,600,850) plus the sieve pan, Sieve Shaker, Digital Scale Balance. HAND TOOLS: Brush
2

5.0 EXPERIMENTAL PROCEDURE 1. The sieve is already cleaned for the test of the experiment. 2. 100grams of silica sand is carefully weighted in to accuracy of 0.01grams. 3. The stack of the sieve is placed according to lowest to the highest number which is 800 micron opening on the Sieve Shaker Octagon 2000 machine. 4. The sieve is make sure to have biggest mesh size on the top. 5. Slowly the silica sand is put into the top of the sieve 6. The machine is on and set to 15 minutes to operate. 7. The weight for each sieve and also pan is recorded on the table after the shaker has stopped in the column (C). 8. The GFN is calculated from the data tabulated. 6.0 RESULTS & DATA ANALYSIS A Sieve No 20 30 40 50 70 100 140 200 270 PAN B Opening (Mic) 850 600 425 300 212 150 106 75 53 C Sand mass (g) 0.72 2.09 20.38 10.8 24.81 19.86 14.87 5.08 1.14 0.17 C= 99.92 D E F Sample AFS AFS % Multiplier Product (C X E) 0.72 2.09 20.40 10.81 24.83 19.88 14.88 5.08 1.14 0.17 10 20 30 40 50 70 100 145 200 300 7.2 41.8 611.4 432 1240.5 1390.2 1487 736.6 228 51 F= 6225.7 D Cumulative Percentage of Mass left
0.72 2.81 23.21 34.02 58.85 78.73 93.61 98.69 99.83 100

NO

1 2 3 4 5 6 7 8 9 10

Total accumulated sand mass (g)

100 %

Original Mass of Sample before 100 Sieving (g) Table 1. Sieve Analysis Data and Calculations

7.0 DISCUSSION OF RESULTS i. Explain briefly what GFN is. Briefly GFN can be defined is the number of size of grain of a particle or in this experiment the silica sand. The GFN is calculated by using the formula GFN calculated from the experiment was 62.76 ii. Based on the GFN value and the distribution obtained, suggest the suitability of the sand for castings. Based on the value of GFN = 62.76 which indicates that the sand is a course sand. It is known that GFN < 50 too coarse will have poor surface quality in casting and GFN >100 too fine will have low permeability, large surface area, thus for the sand that have GFN = 62.76 is suitable for medium casting. iii. Plot the following graphs : (a) Between sieve numbers and percentage of mass retained on each sieve.

Sieve numbers and percentage of mass retained on each sieve

30 25 20 15 10 5 0 20 30 40 50 70 100 140 200 270 PAN

Percentage

Sieve numbers

(b)

Between sieve numbers and cumulative percentages of mass left in the sieve.

Sieve numbers and cumulative percentages of mass left in the sieve

120 100

Percentage

80 60 40 20 0 20 30 40 50 70 100 140 200 270 PAN

Sieve numbers

The graphs shown are the graph plotted for Graph (a) sieve number versus percentage of mass retained in each graph. Graph (b) sieve number versus cumulative percentage of mass left in sieves. For Graph (a), as the sieve number increase, the percentage of mass retained increase too. But as it reaches 40, it drops and at 50 rose up until 70 it continues to drop. The percentage at last sieve number is 0.17 and is the finest of the sand. 8.0 CONCLUSION As, the conclusion the sand grain size is achieved and we managed to get a value of GFN = 62.76 which is a course sand. The shape and the size of the sand does affect significantly to the properties of molding sand. Small grain size provides a better surface finish on the cast part. However large size is more permeable and give rough surface finish. 9.0 RECOMMENDATION From the experiment there is factors that could affect the GFN the factors is the mass loss after sand is put into the shaking devices. In order to reduce the sand loss, students should be more carefully when removing sand at the sieve for weighing. 10.0 REFERENCES 1. http://www.annualreviews.org/doi/abs/10.1146/annurev-physchem-032210103458?journalCode=physchem 2. P.N.Rao, Manufacturing Technology, Foundry, Forming and Welding, 2nd Edition, Institut Teknologi MARA, Malaysia. McGraw Hill, 1998.
3. Seropa Kalpakjian, Steven R.Schmid , Manufacturing Engineering And Technology, Prentice Hall International.