FAB! ~ATION OF A THIN-WALLED ALUMINUM POT FOR DOMESTIC USE BY OZIMEDE JOSEPH A. 2003/15650EM DEPARTMENT OF MECHANICAL ENGINEERING SCHOOL OF ENGINEERING AND ENGINEERING TECHNOLOGY FEDERAL UNIVERSITY OF TEClINOLOGYMINNA NIGER STATE, NIGERIA NOVEMBER, 2008.
FABRICATION OF A THIN-WALLED ALUMINUM POT FOR DOMESTIC USE BY OZIMEDE JOSEPH A. 2003/15566EM A PROJECT REPORT SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE AWARD OF BACHELOR OF ENGINEERING (B.ENG) IN THE DEPARTMENT OF MECHANICAL ENGIREERING FEDERAL UNIVERRSITY OF TECHNOLOGY MINNA, NIGER STATE, NIGERIA NOVEMBER, 2008
DECLARATION I Ozimede Joseph A. (2003/ 15650EM) hereby declare that the project presented in partial fulfillment of the award of Bachelor of Engineering (B. Eng.) degree has not been presented before either wholly or partially for any other degree elsewhere. Information hereby obtained from published and unpublished works of others are acknowledged accordingly. Ozimede Joseph A. 11
CERTIFICATION This is to certify that this project titled Design and fabrication of a thin- walled aluminum alloy pot for domestic use was carried out by Ozimede Joseph A. (2003/15650EM) under the supervision of Prof. R.B Khan and submitted to the Mechanical Engineering Department of the Federal University of Technology Minna, in partial fulfillment of the requirement of the award of Bachelor of Engineering (B.Eng.) degree in Mechanical Engineering. Prof RH Khan Project supervisor Signature and Date Prof RH Khan Head Of Department Signature and Date External Examiner Signature and Date 111
DEDICATION My most indebtedness goes to almighty God, the author and finisher of my faith,for keeping me through the thick and thin right from my cradle to my present time. IV
ACKNOWLEDGEMENT I whole heartedly acknowledge my beloved father Mr. M.A Ozimede who has given me basic disciplinary measures and monastic assistance. I wish to express my appreciation and profound gratitude to my supervisor Prof R.H. khan who out of his myriad of academic activities created time for me, to ensure that this project is a reality. Once again, thank you my menthor, for giving me the necessary guidance to the completion of this project, May God bless you abundantly (Amen). I wish to shower my encomium to my big daddy Elder Goodluck Ozimede for his fatherly advice and unyielding support, may God reward you abundantly (Amen) My reserved appreciation also goes to all my lecturers in my department for imparting their knowledge to me throughout my study. My unreserved appreciation and gratitude goes to my mother Mrs. Mercy Ozimede for her unrelenting effort financially and spiritually towards making my dream come true, may God bless you abundantly. My special gratitude goes to my brothers and my sisters, Ozimede Louis, Ozimede Emmanuel, Ozimede Oshiobugie and Ozimede Loveth for their increasing and enormous support in many ways that cannot be mentioned. Alos, my sincere gratitude goes to Mr. and Mrs. Alenoghena, Alemoh Albert, Adebowale Erukilede and my closest Njoku Vivian for their various contributions Lastly and above all, I ascribe all my adoration to the Almighty God for guiding me from the beginning of this project work to the end. v
ABSTRACT The importance of cooking pot cannot be over emphasized in our society. This is obviously as a result of the over-increasing demand for cooked food in our homes, restaurants, and hotels. The project is therefore to solve problems encountered by most homes, restaurants mostly in the rural areas. When these pots were tested it was observed that the cooking time.was approximately the same time as those fabricated through other means. The need of designs for objects having certain structural shapes that can withstand stress and strain, fulfill over service condition, posses a desirable appearance, and have acceptable cost is remarkable satisfied by this work. The metal (aluminum silicate) can be shaped to almost any configuration and can be produced with only small limitation in size, accuracy and complexity. The process of fabricating a thin-walled aluminum pot are clearly stated in this project, however there is no doubt that considerable improvement could be made in the present design. VI
TABLE OF CONTENT Cover page Title page Declaration Certification Dedication Acknowledgement Abstract Table of content 11 III IV v VI V11 Chapter one 1.0 Introduction 1.1 Background of study 1.2 Objectives 1.3 Justification 1.4 Limitations 1 2 2 2 3 Chapter two 2.0 Literature review 2.1 History of metal casting 2.2 History of metal casting in Nigeria 2.3 Metal casting processes 2.3.1 Pattern making 2.3.2 Molding and core making 2.3.3 Melting and casting 4 4 5 7 7 10 14 Vll
2.3.4 Fettling 2.3.5 Testing and inspection 2.4 Defect in castings 16 16 17 Chapter three 3. 1 Pattern design and allowances 3.1.1 Shrinkage allowance 3.1.2 Machining allowance 3.1.3 Draft allowance 3.2 Time of flow of molten metal through the mould 3.3 Determination of volume of ingot used 3.3.1 Determination of volume of pot 3.3.2 Determination of volume oflid 3.3.3 Determination of volume of handle 19 19 20 20 21 22 22 26 30 Chapter four 4.0 Material selection 4.1 Aluminum and its alloy 4.2 Choice of aluminum-silicon alloy 4.3 Physical properties of aluminum-silicon alloy 4.4 Constructional procedures and processes 4.4. 1 Procedure for pot 4.4.2 Procedure for lid and handle 4.5 cost analysis 4.5. 1 Material cost 35 36 36 37 37 38 39 41 41 Vlll
4.5.2 Labour cost 4.5.3 Overhead cost 4.5.4 Total cost 4.5.5 Cost estimate Chapter five 5.1 conclusions 5.2 Recommendations References 42 42 42 42 43 43 44 IX