Engineering design of centrifugal casting machine

Roni Kusnowo, and Sophiadi Gunara

Citation: AIP Conference Proceedings 1855, 030026 (2017); doi: 10.1063/1.4985496

View online: https://doi.org/10.1063/1.4985496
View Table of Contents: http://aip.scitation.org/toc/apc/1855/1
Published by the American Institute of Physics

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 Engineering Design of Centrifugal Casting Machine
Roni Kusnowo1, a) and Sophiadi Gunara2, b)
1,2
Foundry Engineering Technology Department, Politeknik Manufaktur Negeri Bandung,
Jl. Kanayakan no.21 Dago, Bandung, Indonesia, 40135
a)
Corresponding authors: roni@polman-bandung.ac.id
b)
sophiadi@polman-bandung.ac.id

Abstract. Centrifugal casting is a metal casting process in which metal liquid is poured into a rotating mold at a specific
temperature. Given round will generate a centrifugal force that will affect the outcome of the casting. Casting method is
suitable in the manufacture of the casting cylinder to obtain better results. This research was performed to design a
prototype machine by using the concept of centrifugal casting. The design method was a step-by-step systematic
approach in the process of thinking to achieve the desired goal of realizing the idea and build bridges between idea and
the product. Design process was commenced by the conceptual design phase and followed by the embodiment design
stage and detailed design stage. With an engineering design process based on the method developed by G. E. Dieter, draft
prototype of centrifugal casting machine with dimension of 550x450x400 mm, ¼ HP motor power, pulley and belt
mechanism, diameter of 120-150mm, simultaneously with the characteristics of simple casting product, easy manufacture
and maintenance, and relatively inexpensive, was generated.

INTRODUCTION
Centrifugal casting (Figure 1) is a metal casting process in which metal liquid is poured into a rotating mold at a
specific temperature [1]. Basically, the metal liquid must have a specific temperature to reach the desired length and
thickness prior to the freezing. Centrifugal force will hold the molten metal into a rotating mold. The thickness of
the object is determined by the volume of liquid that is poured into the mold. In the centrifugal casting process,
enhancer and canal system are not required. Thus, the yield will be higher than those of the gravity casting process.
Casting will generate products with higher density level and better mechanical properties than the results of gravity
casting.

FIGURE 1. The Process of Centrifugal Casting

Horizontal centrifugal casting machine has several sections as shown in Figure 2. Centrifugal casting machine
has a capacity to perform and repeat the four processes accurately, namely:
1. To rotate the mold at a certain speed.
2. To drain the liquid metal into a rotating mold.

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3. Once the liquid metal poured into the mold, the machine is able to let the fluid freezes well.
4. Objects cast should be removed from the mold.

FIGURE 2. Horizontal Centrifugal Casting Machine

Solidification of Centrifugal Casting

Solidification process that occurs in centrifugal casting is almost equal to the gravity casting solidification
process that is affected by the heat transfer fluid into the centrifugal casting mold in addition to the mechanical
actions. In ideal conditions, the crystals will grow when the liquid is in contact with the mold wall and will grow up
to the rest of the liquid freezes uniformly toward the interior of the casting and the casting produces smooth without
any shrinkage defects. It can occur in the presence of continuous heat transfer. Solidification is started from the
outside of the body that comes into contact with the mold toward the inside of the object. To avoid shrinkage defects
or center line shrinkage, heat transfer must be uniform to the deepest part of the object and the whole part has been
frozen in prior to the deepest part freezes. It can be achieved if there is liquid flowing in the mold. Unlike the
solidification that happens in the gravity casting process that starts from the parts in contact with the mold and the
core so that the subsequent frozen is the center of the object, so that many defects occur in centreline shrinkage or
shrinkage. The picture of solidification difference between centrifugal casting and gravity casting is presented in
Figure 3.

FIGURE 3. Differences in Solidification Processes

ENGINEERING DESIGN
The design method is a step-by-step systematic approach in the process of thinking to achieve the desired goal of
realizing the idea or ideas and to build bridges between ideas or ideas with the product. The process of making the
design requires a lot of considerations in order to obtain the design that suits the needs. There are several stages in
the creation of design that must be considered in order to obtain an appropriate design. According to [2], the design
method is conducted in stages in the order available in Figure 4.

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 FIGURE 4. Stages of Engineering Design

Engine design was made to obtain horizontal centrifugal casting machine. Engine design includes engine image,
engine parts, manufacture stages, plan making, and assembly plans.

Conceptual Design
Conceptual design is the process of collecting data relating to the design development. The results of this process
are acquired possibilities of design that is suitable for the needs. Several steps must be done in the process of design
concepts, as follows:

x Problem definition
The main problem is how to design a tool or a machine to rotate the mold where the liquid metal will be
poured into it with a temperature of 14000C with a certain speed.
x Information gathering
The information from literature and Internet will be a consideration in the process of making the prototype
engine design.
x Concept generation
Once information and data were collected, a concept of how to work the machine was developed as given
in Figure 5.

FIGURE 5. Working concept of the Machine

After the structure of design concepts was determined, the concept of prototype machine was prepared (Table 1).

TABEL 1. Concept Table of Centrifugal Casting Machine

No Function 1 2 3
1 Change electricity into mechanic Motor AC / Motor Synchronize Motor DC
Induction
2 Change rotation speed torque Gears Chain and sprocket Pulleys and belts
3 Set the speed of rotation inverter Gear ratio The ratio of the diameter
pulleys
4 Rotate the mold permanent mold ceramic mold CO2 process
From Table 1, the variants of concept prototype centrifugal casting machine is demonstrated in Table 2.

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 TABLE 2. Variants of Concept Prototype Machine

Variant Step 1 Step 2 Step 3 Step 4

Variant I 1.1 2.3 3.1 4.3
Variant II 1.1 2.2 3.1 4.1
Variant III 1.1 2.1 3.1 4.3

Concept Evaluation

From the produced concept design, the variants of the working mechanism of the machine were observed and
then evaluated by using weighted evaluation criteria (Table 3). Weight of evaluation criteria used a value of 0 to 1.
TABLE 3. Evaluation of Concepts Variants

No Engineering parameter 1.1± 2.3 ± 3.1 ± 4.3 1.1± 2.2 ± 3.1 ± 4.1 1.1 - 2.1 ± 3.1 ± 4.3
Variant I Variant II Variant III
1 Easy in obtaining materials 1 1 1
2 Easy made 1 0,5 0,25
3 Easy to assemble 1 0,5 0,5
4 Easy to maintain 1 0,5 0,5
5 Economic factors 1 0,1 1
TOTAL SCORE 5 2,6 3,25

Variant 1.1 - 2.3 - 3.1 - 4.3 were the variants selected for the design. A machine with motor AC/induction using
pulleys and belts to transfer the rotation to the roller was selected in which the roller will rotate mold by using CO2
system process.

Embodiment Design
After the design concept was established, embodiment was conducted. This design was designed as reference for
the process of the machine. This design was made by considering the materials, size, shape, and others. The aspects
that must be addressed in the embodiment process are product architecture (Figure 6), machine parts (Figure 7),
configuration design and parametric design. The last two are elaborated in the next paragraphs.

roduct Architecture

Shell Mould

Roller
Shaft
Pillow Block
Frame
Belt
Motor AC

Bolt

Nut

FIGURE 6. Product Architecture

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 No Part Sketch No Part Sketch
Description Description
1 Frame 6 Nut M8

2 Roller
7 Pulley

3 Shaft
8 Shell Mold

4 Pillow
block
9 Motor AC

5 Bolt M6

FIGURE 7. Machine Parts

Configuration Design

The manufacturing process required cutting machines, drilling machines, welding machines and lathes (see
Table 4). The materials consisted of mild steel, ST-60, and aluminum.

TABLE 4. Configuration Design

No Part Description Quantity Process Materials

1 Frame 1 CW B W QC Steel 40x40
2 Roller 4 T B - QC ST-60
3 Shaft 2 T B - QC ST-60
4 Pulley 2 T B - QC Alumunium
5 Shell Mold 1 CW R W QC Mild steel

Parametric Design

The tolerance used is a general tolerance amounting to 0.3.

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 Detail Design
After the design concept was realized, the design was drawn in detail to make it easier for the next process. The
detail design is given in Figure 8.

FIGURE 8. The Detail Design

Bill of Materials

The Bill of Materials (BOM) or the list of parts is a list of each individual component in the product as
demonstrated in Table 5.

TABLE 5. Bill of Materials

Engine Part List

No Part Qty/Engine Materials Part Number
Description
1 Frame 1 Steel 01
2 Shell Mold 1 Mild steel 02
3 Motor DC 1 Standard 03
4 Shaft 2 ST-60 04
5 Pulley 2 Alumunium 05
6 Roller 4 ST-60 06
7 Pillow block 2 Standard 07
8 Bolt M8 12 Mild steel 08
9 Nut M8 12 Mild steel 09
10 Belt 1 Standard 10

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 CONCLUSION
Engine design has been created in such a way to follow the engineering design principle. From the design,
invented horizontal centrifugal casting machine was generated with the machine specification as follows:
x Dimensions : 550x450x400 mm
x Motor Power : 1/4Hp, 1410 rpm
x Mechanism : Pulley and belt mechanism
x Diameter Casting : 120-150 mm Cylinder Casting

REFERENCES
1. Kamlesh. Centrifugal Casting. Available at http://efoundry.iitb.ac.in/TechnicalPapers/dissertations/Kamlesh-
CentrifugalCasting.pdf, accessed on 12 August 2016.
2. Dieter, George E. and Linda C. Schmid. 2000. Engineering Design. New York.

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