Casting

This is my rubber mould in which I will make the casting.This mould is not ecxactly done because of the height of main earning and the height of surronding backround is little bit same.and thats why its base is not strong it was very thin.

I am using Hydrostone, it hardens after addition of water. and the instruction says that one needs to add 32 parts of water to 100 parts of hydrostone.there is need to continues stirring it.

Source:Abhijeet Savant page

then i mixed the water according with ratio and i mixed it continuesly then i put this in my mould

my earing is ready now.te object come from that mould is good but my mould is breakdown because of thin base

After this I decide to make the new mould having large size rather than earning and making the height bigger of surrounding.

Design of pendent

Whatever I made in this assignment its mould is very thin and small ,so I have done new task.In this I made the pendent. for this I design pendent in solid works but this time I made the hollow box large in height.because In my last task I keep that hight large but not too much large because of this positive mould back surface is thin.But this time I take all the precations here.

then I start to make the design in solidworks.for this I take rectangle.fit it lenght as 65*60mm.after that I extrude that part then I make new rectangle and give measurment as 54*60mm and then I use the extrude cut.

After that I make design of the pendent and I use line and arc command for that

then i make extrude to that design and my design is now ready.my design is save as .stl

Making negative mould

I open the fab module I choose there the image type mesh(.stl)then machine roland modela then make rml.then open the main window then I upload the stl image then i choose the end mill 1/8".There are two steps for making the wax mould one is rough cut and after that make the finish cut,but In my case I did only the rough cut with less overlap settings and at the last 30 sec the electricity was gone and thats why I put that mould the surface is not smooth

Then I start to make the positive mould for this I used the rubber solution . I put the rubber solution in the mould and keep it for 1 day but this rubber solution take 3 day for dry after that I picked mould.because of rough surface of wax mould my rubber mould not made smoothly on top side but this time the base of mould is thick.

After making the positive mould I use the hydrostone(gram) and water(mili) for casting in 50:16 ratio.because of rough surface the hydrostone fixed in the surronding of mould.after dry this solution the some parts is come at the surrounding

This is my final pendent product from hydrostone

Then I make the design on it and make the holes by drill machine and put the thred and design it now it looks nice.

Then my friend komal wear this pendent and it is match to her dress and it looks good

Problem faced during this assignment

1.The bubble is come in the mould Because of my wrong techniqe to pour the solution in the mould
2.Material selection is wrong because this material takes the 3 days for dry.
3.because of less overlap setting and only rough cut did ,not finish cut did the surface of wax mould is not smooth.
4.Base is thin because of design problem.

Learning outcomes from these all mistakes

1.First make the design proper means always put the height of surrounding greater than the main object,because it affects when we make the mould from rubber then the base is thick or thin depend on the height of surrounding.

2.Second is choose the correct material for making the mould.Check the drying period because in my case the material takes the 3 days to dry.

3.Third is make wax mould in two step.must use these two end mill for making mould.I use only one and thats why i faced more problem about surface smoothness.I had not put machine on backup and due to which at the end of milling machine stoped so it is must to provide power backup to the machine.

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1.Rough cut-for making the actual design in wax
2.Finish cut-for making the surface smooth

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4.Make correct overlap settings

When we dont provide overlap that time machine provides single path for milling and When we provide overlap that time machine mills object by providing the two paths in which second path overlaps the first one due to which we get smooth surface finish.

5.correct pouring technique

This is more important task in the casting because when we pour the material at that time the bubbles comes in that mould and because of bubble the mould damages so do the proper pouring.
1.After pouring the solution in the mould then make vibration.
2.Make tapping after pouring the solution

6.Base of mould

by improving these all mistakes i will make good casting in future

Conclusion

I learn so many things after my mistakes and I document all the things proprly.now I understand importance of pouring,designing and how to mill the wax for proper mould to get the smooth surface.