CONSTRUCTION AND TESTING OF A MECHANICAL STIRRING MACHINE FOR FOUNDRY WORKSHOP

ABSTRACT This project focused on the design, construction, and testing of a mechanical stirring machine for foundry workshop applications. The study aimed to address challenges associated with manual stirring, such as inconsistent mixing, operator fatigue, and safety risks from exposure to molten metals. The designed machine utilized a 1 HP electric motor connected to a geared reduction system, which provided adequate torque for uniform mixing of molten materials. The gear reduction ratio was determined to be 2:1. Locally sourced materials such as mild steel, stainless steel, and cast iron were employed in the fabrication to reduce production costs. The machine components included a motor, gearbox, shaft, impeller, bearings, frame, and control panel. Testing results revealed that the mechanical stirrer achieved effective and uniform mixing of molten aluminum and reinforcing particles, improving composite homogeneity and reducing operational hazards. The machine demonstrated an operational efficiency of 85% and had a stirring capacity of approximately 5 liters of molten metal. The project concluded that with proper design analysis and material selection, a reliable and cost-effective stirring system could be developed locally to enhance safety, efficiency, and productivity in foundry operations.