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the assignment topic is : Melting aluminium by using electromagnetic cylinder
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Table of Contents
LIST OF TABLES .........................................................................................................ii
LIST OF FIGURES .......................................................................................................ii
LIST OF SYMBOLS AND ABBREVIATIONS ......................................................... iv
CHAPTER 1 INTRODUCTION ................................................................................... 5
Introduce the project problem .................................................................................... 5
Aim and objectives of the investigations ................................................................... 7
Scope of the investigations......................................................................................... 7
Chapter summary ....................................................................................................... 8
CHAPTER 2 LITERATURE REVIEW ........................................................................ 9
Summary .................................................................................................................. 21
CHAPTER 3 EXPERIMENTAL SETUP & METHODOLOGY ............................... 23
Aluminum................................................................................................................. 23
Properties .............................................................................................................. 24
Characteristics ...................................................................................................... 24
Uses ...................................................................................................................... 24
Electromagnetic Melting Process Overview ............................................................ 25
Electromagnetic Induction ....................................................................................... 29
Electromagnetic cylinder.......................................................................................... 30
EQUIPMENT DESIGN ........................................................................................... 33
EXPERIMENTAL ................................................................................................... 38
Calculation of Power and Heat Losses ........................................................................ 42
CHAPTER 4 RESULTS AND DISCUSSION ............................................................ 45
Heating Estimates ..................................................................................................... 48
Magnetic flux density ............................................................................................... 49
CONCLUSIONS ...................................................................................................... 50
Melt rate ................................................................................................................ 50
Operating KW....................................................................................................... 50
RECOMMENDATIONS ......................................................................................... 50
FUTURE WORK ..................................................................................................... 51
References ................................................................................................................ 52
i
LIST OF TABLES
Table No.
Title
Page No.
1
Potential Energy Reductions
14
2
Design analyses Results
19
3
Properties of Aluminum
24
4
Prerequisites design of the electromagnetic cylinder.
34
5
Design analyses Results
47
6
Experimental, Analytical Equation and FEM Model
49
Heating Rate
LIST OF FIGURES
Figure
Title
Page No.
No.
1
Uses of power in metal casting industry
6
2
The schematic diagram of the melting equipment
10
3
Relationship between temperature and time during
17
melting
4
difference in mechanical properties of the sample
18
heat-treated at various heating rates
5
Magnetic flux
27
6
current sheet properties
28
7
Magnetic field
30
ii
8
electromagnetic flux density variation with coil
40
shape factor (Dcs/lc)
9
electromagnetic Cylinder
41
10
Aluminum drilling
42
11
Temperature variation in aluminum sample
48
LIST OF SYMBOLS AND ABBREVIATIONS
H
-Height of aluminum piece
D
-Diameter of aluminum piece
𝑚
- Mass of charge
Ac
- Area of the coil
Lc
- Inductance of the coil
- Magnetic flux density
- Infinitesimal vector length
C
- Specific heat capacity of aluminum
- Permeability of free space = 4𝜋 𝑥10−7 𝐻/𝑚
-Relative magnetic permeability
- Current density
- Infinitesimal vector area
- Total enclosed current
- Magnetic field intensity
-Electrically determined power
- Calorifically estimated power
-Mass flow rate of the water
-Heat capacity of the water
-Change in temperature
Ploss
- Heat losses
iv
CHAPTER 1 INTRODUCTION
Introduce the project problem
Melting of glass, metals, and different materials has been an indispensable
manufacturing process for a several centuries, molten production that can be emptied
and molded into several desired forms. Despite the fact that the essential procedure
keeps on being the same, the usefulness of cast items has made considerable
advancement. The procedure that made equipment and outstanding products for just
privileged individuals during the Age of Bronze, contributes parts utilized as a part of
more than 90% of fabricated merchandise in our public currently. As from the
beginning of the industrial age, the colossal advance in the melting process of metals,
the scope of molten materials, the science and thermal regulations, and the end
products complexity has facilitated molding of components in building a wide sorts of
equipment. For instance, cars, power generators, railroad autos, oil pipelines, military
equipment, and therapeutic instruments.
The energy effectiveness of a melting furnace to a great extent depend on the
productivity of the melting procedure. Melting process involves several steps, which
includes heating, treating, allowing and transportation into mold or die openings to
form a molding. The melting procedure is not only accountable for the energy
utilization but also cost- efficiency of production of molds, however it is likewise
important to the quality regulation, physical and chemical composition of the end
product.
5
Figure 1
Melting is profoundly energy exhaustive, then the metal molding sector is one of
biggest utilizers on energy in the world and especially Oman manufacturing industry.
In the sector, the expenditure was $1.2 billion on electricity and fuels consumptions
only in 1998. The worry over the energy proficiency of procedures has been
incrementing with the current increasing expenses of energy. The metal molding
sector is particularly affected by the expansive value fluctuations of petroleum gas as
it is the sector’s biggest energy source. Aspects such as rising energy demands,
intensified by huddles in energy costs from world occasions and cataclysmic events
(like and Rita Hurricanes Katrina), will proceed with the upward pattern in energy
prices, calling for the requirement for designing energy proficient mitigation measures
for the melting processes.
Despite the fact that the energy utilization in the melting procedure has been a huge
worry in casting operations, the industry keeps on utilizing melting techniques with
low energy efficiencies. Researches have demonstrated that by executing best practice
innovations, aluminum and iron melting can spare roughly 2.5 and 0.9 million British
thermal units for each ton respectively. In light of the fact that aluminum and iron
molding volumes contribute over 79percent of the aggregate molding volume,
prospective savings in melting these metals are significant. Endeavoring to decrease
energy consumed during the melting of iron and aluminum metals demonstrates a
promising way to bringing down production expenses in casting and, thusly, chopping
down the manufacturing expense for the whole Oman producing industry.
Aim and objectives of the investigations
The objective of this research was to investigate the ideas of utilizing electromagnetic
cylinder in melting aluminum that may drastically lessen the energy utilization. The
research will direct the aluminum production enterprises in finding significant
research studies for improving energy proficiency.
The research intends to give an introductory idea preceding the "Elephant Challenge"
breakthrough with regards to cutting edge melting innovations. It attains its objective
by studying the working principles of an electromagnetic induction furnace as one of
the viable technologies, which can be used to reduce energy consumption in casting
industries in Oman. The study will further involve the design of a simple
electromagnetic cylinder. The workability of the electromagnetic cylinder will be
tested against analytical formulas and FEM model.
Scope of the investigations
The Scope of the research incorporated aluminum-melting process in the metal
casting sector, both in Oman and global industries. In spite of the fact that, the report
concentrates on aluminum casting, the electromagnetic induction talked about in this
report are by and large appropriate to glass, iron and steel castings.
Chapter summary
The metal molding sector is a standout amongst the most energy consuming industry
divisions with the melting procedure recurrenting over half (60percent) of its energy
utilization. Despite the fact that its high-energy costs have been a challenge for metal
casting investors, the industry keeps on utilizing melting techniques with low energy
effectiveness.
The apparent straightforward melting process involving heating of metals to transform
them into molten form is really mind boggling, including a progression of steps that
results into energy and material waste. These wastes are associated to various aspects
such as unnecessary convection, radiation and conduction, gas leakages, and metal
wastes. The degree of the waste relies upon the technique in melting, the fuel utilized,
and the design of the furnace.
Metal melting process consumes a considerable amount of heat, ordinarily requiring
some sort of intensive energy-devouring melting system. Nonetheless, with a little
current and a copper coil, you can melt a piece of metal using an electromagnetic field
while suspending it mid-air amid the procedure. The arrangement is simple since it
utilizes electromagnetic induction melting to heat the metal piece to molten state
without strapping on a visor.
CHAPTER 2 LITERATURE REVIEW
Ren, 2014 examined the electromagnetic stirring and directional hardening and remelting process for the degassing of aluminum combination melt. The degassing
practicality and the gas development and accumulation mechanism amid the
procedure were analyzed. In addition the impacts of different rates of pulling-down
and re-melting on the level of degassing and physical characteristics of the alloy were
discussed. The close eutectic molding AI-Si alloys were utilized as a part of this
examination and arranged by the blend of metallurgical review silicon and
unadulterated aluminum.
Graphite cauldron was used to hold the alloys and at first set amidst the coin zone of
the electromagnetic blast furnace, and after that molten at 1073 K. In the wake of
being melted, the work pieces were pulled up and down 12cm at various pulling rates
as they cool and solidify. After solidifying, the work pieces were cut open, measured
the porosity region division identified by porosity estimations, refined with the
standard metallographic procedures, captured by advanced camera, and finally
determine the elasticity and tensile strength with the use of universal testing machine
and significant estimations. The work pieces were then returned to the graphite
crucible and re-molded, going over the past stages a couple times.
Amid the entire melting and solidifying processes, argon gas was currented into the
Quartz tube continuously to avoid the oxidation of the dissolve. The schematic outline
of the setup was as in figure 2 below.
Figure 2
The outcomes demonstrated that the degassing effectiveness improved with the
decrease in rates of pulling-down, and upon re-melting, the porosity ratio to surface
area of aluminum alloy was additionally decreased. The physical and strength
characteristics of aluminum alloy, for example, elasticity and tensile strength, were
extraordinarily increased. It gives a smart concept to the degassing of molten alloy,
which is great prospective for the manufacture of top notch aluminum alloys.
Spitans, 2017 studied dribble and spillage free technique for electromagnetic floating
melting of metallic specimens in horizontal and perpendicular multi- frequency fields.
Mathematical simulation was utilized to come up with an investigational furnace for a
steady floating melting of aluminum work piece of varying weights. The scale-up of
the technique was approved by various experimental trials with aluminum work
pieces of up to 500grams. Components of tentatively experiential fluxs and variability
of solid work pieces were analysing utilizing geometric simulation.
The examination demonstrated that by methods for horizontal and perpendicular
electromagnetic fields of various frequencies, contrasted with the floating in ordinar...