THE OXFORD COLLE GE OF ENGINEERINGHOSUR ROAD, BOMMANAHALLI, BANGALORE - 68

DEPARTMENT OF MECHANICAL ENGINEERING

LESSON PLAN Date: 17/01/2015

Subject code /Title : 10ME838 / Foundry Technology Course / Branch : Mechanical EngineeringSemester / Academic Year : 2015

Objectives of Course : To gain the knowledge in advanced manufacturing methods towards increasingly complex needs of current industriesTo understand the basics of the present trends in metal casting.

Prerequisites : Basics of manufacturing process-1

Module/ Unit

Topic NoDate

Topic

Books Referred & Pages

1.

1.1 05/02/15 Foundry Metallurgy: Oxidation of liquid metals, Principles of metal casting, Heine

Loper & Rosenthal TMH - 20051.2 06/02/15 gas dissolution in liquid metals, Principles of metal casting, Heine

Loper & Rosenthal TMH - 20051.3 07/02/15 methods of degassing, fluidity,

factors affecting fluidityPrinciples of metal casting, Heine Loper & Rosenthal TMH - 2005

1.4 12/02/15 fluidity tests, hot tearing Principles of metal casting, Heine Loper & Rosenthal TMH - 2005

1.5 13/02/15 shrinkage of liquid metals Principles of metal casting, Heine Loper & Rosenthal TMH - 2005

2.

2.1 14/02/15 Casting Design: Introduction to casting design

Pr Principles of metal casting, Hein e Lo Loper& Rosenthal TMH - 2005

2.2 19/02/15 redesign considerations Principles of metal casting, Heine Loper & Rosenthal TMH - 2005

2.3 20/02/15 design for minimum casting stresses, Principles of metal casting, Heine Loper & Rosenthal TMH

2.4 21/02/15 design for directional solidification, Principles of metal casting, Heine Loper & Rosenthal TMH

2.5 26/02/15 design for metal flow, safety factors, Principles of metal casting, Heine Loper & Rosenthal TMH

2.6 27/02/15 design for low pattern cost and model making as an aid in design.

Principles of metal casting, Heine Loper & Rosenthal TMH

3.

3.1 28/02/15 Solidification Of Castings: Crystallization and development of cast structure - nucleation, growth and dendritic growth

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

3.2 05/03/15 Structure of castings – significance and practical control of cast structure

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

3.3 06/03/15 grain shape and orientation, grain size,

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

3.4 07/03/15 refinement and modification of cast structure.

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

3.5 12/03/15 Concept of progressive and directional solidification,

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

3.6 13/03/15 solidification time and derivation of Chvorinov’s equation, influence on mold characteristics and cast metal.

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

4.

4.1 14/03/15 Risering And Gating: Need for risering, general considerations of risering,

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

4.2 19/03/15 riser shapes, riser size, and location. Principle of Foundry Technology,

P. L. Jain, 5th Ed., TMH – 20064.3 20/03/15 Requirements of a riser. Sand,

insulating, and exothermic materials used for risers

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

4.4 26/03/15 Riser feeding distance and theory of risering. Internal chills, external chills

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

4.5 27/03/15 use of mould materials of different chill capacities, padding for directional solidification

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

4.6 28/03/15 Open type and blind risers Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

4.7 09/04/15 Riser treatment using exothermic and insulating compounds.

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

4.8 10/04/15 Gating system – theoretical consideration of gating, laws of fluid flow,

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

4.9 11/04/15 turbulence in gating system, use of ceramic foam filters in gating, need for tapered sprue, gating ratio, simple problems.

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

5.

5.1 16/04/15 Special Moulding Techniques: Principles, materials used

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

5.2 17/04/15 process details and application of no-bake sand systems

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

5.3 18/04/15 vacuum moulding, flaskless moulding,

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

5.4 23/04/15 high pressure moulding Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

5.5 24/04/15 CUPOLA MELTING: Developments in cupola melting – hot blast cupola,

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

5.6 25/04/15 water cooled cupola, balanced blast cupola

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

5.7 30/04/15 cokeless cupola, cupola charge calculations.

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

6

6.1 02/05/15 Ferrous Foundry: Melting procedures, casting characteristics

Principles of metal casting, Heine Loper & Rosenthal TMH - 2005

6.2 14/05/15 production, specification, and properties of some typical steels,

Principles of metal casting, Heine Loper & Rosenthal TMH - 2005

6.3 15/05/15 grey cast iron, malleable iron, and Principles of metal casting, Heine Loper & Rosenthal TMH - 2005

6.4 16/05/15 spheroidal graphite cast iron castings Principles of metal casting, Heine Loper & Rosenthal TMH - 2005

7

7.1 21/05/15 Non-Ferrous Foundry: Melting procedures, casting characteristics

Principles of metal casting, Heine Loper & Rosenthal TMH

7.2 22/05/15 production, specification, and properties of some typical aluminum,

Principles of metal casting, Heine Loper & Rosenthal TMH

7.3 23/05/15 copper, and magnesium based alloy castings.

Principles of metal casting, Heine Loper & Rosenthal TMH

8

8.1 Ext.class Modernization And Mechanization Of Foundry: Need for modernization,

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

8.2 Ext.class mechanization, moulding and core making,

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

8.3 Ext.class melting, pouring, shake out equipment and fettling,

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

8.4 Ext.class dust and fume control, material handling equipmentsfor sand moulds and cores,

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

8.5 Ext.class molten metal and castings, reclamation of sands.

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

8.6 Ext.class Pollution control – norms, and agencies

Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006

Self-study Topics (Out –of- Syllabus)Sl. No. Self –study Topics Suggested Reference

1 Advanced manufacturing methods Castings, John Campbell, Second edition, Elseivier

2 Present trends in industries over ferrous &non-ferrous metals Manufacturing Process, I, Dr. K. Radha Krishna 5th Edn

3 Reinforcing of fibres in metal matrixes Production Technology, HMT Tata McGraw Hill. 2001

4 Latest trends of composite manufacturing Handbook: Machining Volume 16, Joseph R. Davis (Editor)

Assignment TopicsSl. No. Assignment Topics Submission due on

1 Manufacturing of polymer matrix composites 10/3/2015

2 Manufacturing of metal matrix composites 15/4/2015

3 Manufacturing of ceramic matrix composites 01/5/2015

Students Feedback about the course from Last Year:1.2.

Action Plan proposed to accommodate the Feedback:

1.2.

HOD Faculty