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ABSTRACT

For tomorrow engineers to play their role effectively, they must learn from yesterdays engineering work and if necessary modified what they have learnt.  This project is therefore on the design and construction of a 505 Peugeot Piston Mould. For the design and construction of a 505 Peugeot Piston Mould to be a success, it must involve casting.  Casting as a production process involves pouring of molten meral into a mould that contains the shape of the required part and on solidification a duplicate of the original part will have been formed.  This part which would have a rough surface is subjected to machining for surface finishing. This is exactly what we have done.  In the production of the Piston Mould, we produced the pattern (Internal shape) which will guide us in getting the required shape, the material chosen which was mild steel was cut to required dimension, which followed by milling and shaping etc, all of which can be seen in chapter 4 (sequence of operation) As a result, our casting is diecasting with sand core.  We used Aluminum scraps which was milted to a temperature and poured into the mould, which after a particular time gave us the required shape of the pison.  From the foregoing, we see that product and casting, if taken seriously and put into productive practice will not only be a source of making money but a means of converting wastes to wealth.

 

TABLE OF CONTENTS

CHAPTER ONE:       INTRODUCTION

1. Introduction                                                                                                            1

CHAPTER TWO

1. Literature Review                                                                                       3

2.1      Introduction to Casting Processes                                                         6

1. Types of Casting Processes                                                                      6
2. Die/Semi Die Casting                                                                                 7         
3. Advantages of Die Casting                                                                       8                                                                     
4. Core Pattern Making                                                                                 9
5. Core Box                                                                                                       10
6. The Core                                                                                                       10
7. Furnace Forcasting                                                                                                11
8. Layout of Furnace                                                                                      11
9. Preparing Furnace Forcasting                                                                12

CHAPTER THREE

3.0      Material Selection                                                                                      14

3.1      Malleability                                                                                                  14

3.2      Ductility                                                                                                        14

3.3      Tenacity                                                                                                        15

3.4      Hardness                                                                                                      15

3.5      Toughness                                                                                                    15

3.6      Compressibility                                                                                           15

3.7      Elasticity                                                                                                        15

3.8      Fatique                                                                                                          16

3.8      Weldability                                                                                            

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