ISSN : 2249-5762 (Online) | ISSN : 2249-5770 (Print) IJRMET Vol.

4, Issue 2, May - October 2014

Design and Fabrication of a Wind Mill Hub

Abu Thomas Cherian
Mangalam College of Engineering Ettumanoor, Kerala, India

Abstract III. Drawings

For centuries, windmills and watermills were the only source of
motive power for a number of mechanical applications, some of
which are even still used today. From time to time many materials
were used to construct these structures. In the late 20th century
the use of ductile iron(sg iron) found very effective for wind mills
due to its high strength Ductile iron is not a single material but
is part of a group of materials which can be produced to have a
wide range of properties through control of the microstructure.
This paper deals with the design and fabrication of a wind mill
hub using SG iron.

Keywords
SG Iron, Wind Mill Hub

I. Introduction
Casting is one of the oldest manufacturing process which dates Fig. 1: Top View of HUB (All In MM)
back to approximately 400BC. Earlier castings were probably
made out of copper, silver, gold, bronze, etc. Perhaps the earlier
casting of cast iron were those of cannon shot and grave slabs. The
first foundry center came into existence in the days of the Shang
dynasty (1766-1122BC) in china. A number of foundries using
cast iron as a structural material came into being after Industrial
Revolution (in Britain).
The collapse of the Toy Bridge in 1879 forced people to go beyond
the rudimentary judgment of the then molders and to study the
pounding variables and their effect on the properties of structures
The middle part of twentieth century. Saw marked development
in founding .Newer techniques came in to existence. Engineering
institutes started teaching metal casting as an independent
subject

II. Material Used

Ductile iron is a family of alloys which combine the principal
advantages of graycast iron with steel. Ductile iron consists of Fig. 2: Cross Sectional View (All In MM)
graphite spheroids dispersed in matrix similar to that of steel .; the
matrices can be similar. The ease with which ductile iron can be IV. Casting Design
processed and cast into is very dependent on the carbon content. Castings are born on designers drawing board, but the final
shapes is often altered during the course of its development. As
Properties machine elements tools or other objects, their functional purpose
High castability is given, first and fore-most attention by the designer. Ultimately
Higher machninability compared to steel . after testing the design possible modifications are made. The next
Improved corrosion resistance step is manufacturing.The following factors should be considered
Good vibration damping capabilities when designing a casting.
Ductility Design for minimum casting stress. External corners should
Low melting point. be rounded. Replace sharp angles and corners with suitable
High strength and toughness radi.
Table 1: Chemical Coposition SG Iron Design for direction solidification. Bring minimum number
Element % Composition of sections together.
C 3.6-4.2 Design for metal flow: For SG iron the minimum casting
thickness should be not be less than 8 mm.
S .5 - 1
Design for minimum costing
Si 1.25-2.0
Mn 0.35 V. Design of the Gates
P 0.08 Steps in Design
Ni 0.0-1.0 Weight of the casting = 2410kg
Mg 0.05-0.08 From normal foundry practice it is found that the yield for S.G

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IJRMET Vol. 4, Issue 2, May - October 2014 ISSN : 2249-5762 (Online) | ISSN : 2249-5770 (Print)

iron is 70-75%. That means if 100kg of molten metal is poured VI. Design of RISER
only 70-75% will be used by the casting remaining 25 to 30% is For the casting of the wind mill hub, conventional risering using
used for the gating system. open risers is used.
Taking yield 70% Normally risers are placed at regions of heavy thickness
Weight of the molten metal to be used = 3442.85 For the hub casting the regions of heavy thickness are
=(2410/70)*100 = 3442.85kg 1. At the 3 flanges
2. Top central portion
Riser on flanges
Riser diameter = modulus of riser x 4
Modulus of riser= modulus of casting x 1.21
Cross sectional area at flanges is Rectangular
Width = 225mm (a)
Length = 50mm (b)
Modulus of Casting = a*b/2*(a+b) = area/perimeter
= 225*50/(2*275)= 20.45mm
Therefore modulus of riser =20.45*1.21
=24.75mm
Riser diameter =24.75*4
=99mm
100mm
Height of the riser = 100*1.5
Since the diameter to height ratio of riser is normally taken
1:1.5
Neck of the riser
Graph :1 Pouring Weight (lb) Vs Choke Area (in2) Neck diameter is given of the riser diameter
= 100mm/2 = 50mm
Values obtained from graph Risers at central top part
Choke area = 8.6 in2 The top central part is almost like a cylindrical part. In cylindrical
Pouring time 57sec parts a riser can properly feed only up to a maximum of 1200(600
Choke area means the lowest cross sectional area anywhere in a on each side). So a minimum of 3 risers are necessary.
gating system Modulus of casting = (a*b)/2(a+b)
Choke area = 8.6in2 a = 225mm
Selecting number of gates b = 85mm
From the sprue the gate should start only after a 150mm length = 225*85/2(225+85)
The distance between two gates should be greater than 90mm = 30.84mm
Heavy thickness should be provided with a gate Modulus of riser = 30.84*1.21
Selecting number of gates = 37.324mm
From the sprue the gate should start only after a 150mm length Diameter of riser = modulus of riser*4
The distance between two gates should be greater than 90mm = 37.324*4
Heavy thickness should be provided with a gate = 149.2983mm
There for a total of six gates needed hub 150mm
Total choke area = 4.6 in2 Height of the riser = 150*1.5 = 225mm
Choke area of each gate = 8.6in2/6 = 1.433 in2 Since the diameter to height ratio is 1.5
The cross section of a gate is shown in the figure Neck of the riser is riser diameter = 150/2
The ratio between the length and the height is 4:1 =75mm
Therefore Area of the gate = 4t2 In normal practice riser patterns are not manufactured for each
4t2 = 1.433in2 casting. Some standard sizes are available. They are 75, 100,
t2 = .3583t 150, 200 and 225.
t = (.3583)
= 0.598in Design of the Runner and SPRUE
=15.2mm The gating ratio normally selected for SG iron is 4:8:3.
= 15mm (spure:runner:ingate)
Length = 4x15 = 60mm Steps in design of runner
Total runner area of pressurized system = (8/3)* choke area =
(8/3)* 8.6 in2 =22.93 in2
Area of runner = 2a2
2a2 = 8.6 in2
a = 2.076 in
Fig. 3: Cross Section of in Gate a = 5.080cm
= 50.80mm
To introduce a taper 1.5mm is added to one side and subtracted 51mm
from the other side. Height = 2*a = 102mm

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Design of sprue (pressurized)

The shape of sprue is generally tapering downwards
Sprue area at bottom = (4/3)*8.6 in2
= 11.46 in2
r 2
= 11.46 in2
r
2
= 3.649 in2
r = 1.910inch
r = 46.80mm
Nearest sprue size available is 50mm

VII. Molding Box Selection

Most suitable size available is of the following specification (One
half)
Cross section = 200mm2
Height = 550mm
Volume of molding box = 200*2000*550
= (area * height) Fig. 6: Core Assembly
= 22*108 mm3
Total weight of casting = 3442.85kg Table 1: Standard Sand Mixing Proportions
Density of SG iron = .225 pound/in3 CHEMICALS AMOUNT (Kgs)
Mass / volume of casting = density
Sand 500
Volume of casting = mass/density (pound/(pound/in3))
= 7655/.255 Sodium silicate 22.5
Casting volume = 30020 in3 in both boxes Density of compacted Iron oxide 2.5
sand (co2) needed for large castings = 1.6 pound/in3 Yellow dextrin 2.5
Total volume of the box = 2.2m3*2
= 4.4m3 VIII. Metal Melting

= 30299.02kg
= 30.3 ton A. Induction Furnace Melting
The induction furnace used is the low - frequency, 60 - cycle
type. The capacity of the furnace is 6 tons. These furnaces can be
operated either for cold melting or for duplexing. Very close control
must be exercised over raw materials in these furnaces since the
rust on scrap and other slag forming ingredients rapidly. Extremely
close control of composition of metal temperature is possible in
those furnaces, so quality S.G. iron can be produced.
A Y-block is used to produce tensile bar specimen for customer-
acceptance test-and for conducting distractive tests on the metal.
There is a standard Y-block pattern of heavy casting, this pattern is
placed in the molding box and connected with the gating system.
So that the part of the pouring metal will be filling the Y-block
cavity. And solidifies to form the solid Y-block for conducting
tests

B. Graphite Shape and Size

Fig. 4: Core Assembly

Fig. 5: Core Bottom Half Fig. 7: Graphite Shapes in Ductile Iron

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Quality ductile iron is produced so that graphite is developed as 5. A splash-core is provided at the bottom of the sprue
spheroids. A number of other graphite may develop, however if 6. Air-vents should be properly made for the escape of gases.
the process is not carried out property. The chart classifying these 7. Chills of size 70*70*50 are placed at the heavy thickness
graphite shapes have been proposed and presented in the figure. regions of the casting to promote directional-solidification
Type 1 graphite is the accepted graphite from of S.G. iron although
presence of type II graphite will have little effect on properties. X. Solidification Proces
Up to 10% type and the remaining type III graphite will have no The fundamentals of heating and cooling are shown in the graph
notice able effect on properties. Increases amount of type III is not given below
desirable. Type IV and V are undesirable and have significantly
low mechanical properties.

Fig. 9: Temperature Range of Solidification

1. Liquid metal cools until freezing begins at point 1. At this

temperature solid austenite dendrites begins to form and grow
until the temperature at point 2 is reached.
2. Eutectic freezing begins as the point 2 is reached. The
eutectic solid which formed is a mixture of austenite and
graphite. As the temperature has dropped to point 3, freezing
is completed.
3. At the end of freezing, the structure consist of the solid
developed during step A and B. (austenite and graphite)
4. Further cooling between points 4 and 5 results in the
precipitation of carbon from the austenite present since
Fig. 8: Graphite Size in Ductile Iron austenite may contain as much as 2% carbon, but only (.60-
.80) % as the temperature decreases to point 4. The excess
The graphite shapes developed in S.G. iron mainly dependents carbon is precipitated as graphite in nodular iron.
on pouring temperature, casting section size, amount of effective 5. Between points 4 and 5, the final change occurs in the solid
magnesium added and inoculants. In general the poor graphite during cooling. Austenite transforms over the temperature
shapes are developed low pouring temperature, heavy section range 4 to 5. With the most favorable graphitizing condition,
sizes, insufficient magnesium added and low carbon - equivalent. only ferrite is formed. With less severe graphitizing condition
Six sizes of graphite spheroids have been proposed. Among them ferrite and peralite are formed. In nodular cast iron, mixed
5 and 6 are the most desirable sizes. This mainly depends on structure of ferrite and pearlite forms a bulls eyes of ferrite
pouring temperature and thickness of the section. around graphite spheroids.

IX. Casting XI. Fettling

Fettling is the name given to cover all those operations which
A. Practical Considerations helps in giving the casting a good appearance after the casting
1. Over gassing will produce white patches on the surface of the has been taken out from the mould.
mould and core due to the presence of sodium bicarbonate.
Optimum range 10 20 (lbs/in2 min) XII. Inspection and Testing
2. A co2 cores are to be painted with alcohol based refractory Inspections has to do with the observation of the process and
washes (zircon) and graphite. products of manufacture to ensure the presence of desired qualities.
This is for getting better surface finish and to avoid sticking Testing ,on the other hand ,specifically refers to the physical
of pattern to the mould. performance of operations to determine quantitative measure of
3. Preheating of ladle is done with help of firewood. (up to certain properties such as mechanical , chemical.
500oC) Inspection procedures and test may be classified as follows
4. Re-inforcement bars and hooks are placed inside the core for 1. Visual inspection for defects
better handling and better strength 2. Geometric checking for shape and dimensions

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3. Chemical tests
4. Microscopic test Abu Thomas Cherian received his B
5. Testing for mechanical properties tech. degree in Mechanical engineering
6. Non- destructive tests from M B C College of Engineering
peermade, kerala India, in 2010, the
XIII. Conclusion M.Tech. degree in Machine design
The wind mill hub is manufactured and it passed all the quality from Saintgits college of Engineering
tests. kerala, India, in 2012. Respectively,
He is currently Working as Assistant
professor in mechanical department
XIV. Acknowledgement at Mangalam college of engineering
I would like to thank Mr. T D S Kartha (Engineer in Charge of Ettumanoor, Kerala, India.
Mechanical Department) and all the staff members of AutoKast
Cherthala, Kerala for helping me to complete this work
successfully.

Referance
[1] O.P Khanna,Foundry Technology, 2nd ed.,Danpat Rai,
New Delhi, 2006.
[2] Peter Beely,Foundry Technology, 2nd., ed.,Elsevier India,
New Delhi, 2005.
[3] Richard W Heiene, Carl R loper, Phlip C Rosenthal,
Principles Of Metal Casting, 2th ed.,Tata Mc Graw-Hill ,
New Delhi, 2002.
[4] O.P Khanna,Material Science And metallurgy, 10 th ed.,
Danpat Rai, New Delhi, 2010.

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