This thesis presents a thorough study on the design and manufacturing of casting moulds for the housing of a hand-operated seed grinding machine. The primary objective is to develop cost-effective and durable casting solutions tailored to meet the practical needs of rural communities. The research is structured into several key phases:

1. Conceptualization and CAD Modelling: The project began with comprehensive CAD modelling of the seed grinding machine components. Emphasis was placed on the housing unit, which was subdivided into distinct parts, namely, the inlet funnel, cylindrical chamber, vertical support bracket, reinforcement gusset, and mounting base, to facilitate precise mould design and later assembly.
2. Geometric and Mould Design: Detailed geometric analyses were conducted to design the upper (cope) and lower (drag) mould forms. The study carefully considered factors such as parting lines, draft angles, and cooling channel placement, ensuring the moulds would support effective die casting while minimizing defects such as flash and porosity. Calculations involving gate area, clamping force, and shrinkage allowances were performed to optimize the mould design and accommodate material behaviour during cooling and solidification.
3. Manufacturing Technology and Process Optimization: The thesis explores various manufacturing techniques with an emphasis on CNC milling technology and Electrical Discharge Machining (EDM) for creating intricate mould geometries. Material selection played a critical role, with tool steels (e.g., H13, P20) chosen for their ability to withstand high temperatures and pressures, and stainless steel 304 recommended for the final housing parts. Post-machining processes, such as heat treatment, were integrated to enhance surface finish and structural integrity, thereby extending mould life.
4. Finite Element Analysis (FEA) and Quality Assurance: Finite element analysis was employed to evaluate stress distribution, deformation, and safety factors of the assembled housing. The FEA results provided essential insights that guided design modifications to improve performance under operational loads and ensure reliability during the die casting cycle. Quality control measures, including coordinate measuring machine (CMM) inspections and surface profilometry, were implemented to verify dimensional accuracy and surface integrity.
5. Results and Implications: The findings of this research indicate that the proposed mould designs significantly improve the manufacturing efficiency and durability of the hand-operated seed grinding machine’s housing. The optimized casting process not only reduces material waste and production costs but also enhances the mechanical performance and longevity of the final product. The study contributes to sustainable manufacturing practices by offering a viable solution for producing robust, low-cost agricultural machinery components.