Construction of a Low-Cost Electric Resistance Furnace for Simple Casting Operations

Abstract

This study presents the design, construction, and performance evaluation of a low-cost electric resistance furnace tailored for simple casting operations in educational and small industrial settings. A 4 kg capacity furnace was developed, focusing on energy efficiency, temperature control, and affordability. The design process included the simulation of key furnace parameters using ANSYS Fluent 14.5 to optimize factors such as furnace chamber volume, power supply, wall thickness, and heat resistance wire. The furnace incorporated nichrome wire for the heating element, light refractory bricks for insulation, and a 230V single-phase power source. Performance testing revealed that the furnace could reach melting temperatures of up to 1180°C, with a melting time of approximately 45 minutes for aluminum. The energy consumption was recorded at 1.5 kWh per hour, with minimal heat loss (below 10%) and operational durability for 30 continuous hours. The results indicate that the furnace is a viable, cost-effective solution for small-scale casting operations, offering an efficient alternative to more expensive industrial furnaces. Future improvements could include the integration of automated temperature control and further compact design optimization.