Course Specifications
Relevant Programme
B.Sc. in Engineering
Department offers the programme
Faculty of Engineering (Mechanical
Engineering)
Department offers the course
Department of Production Engineering
and Mechanical Design
Mechanical Engineering
Scholar year
2nd year Production Engineering and
Mechanical Design /First Semester
Date of specification approval
2006
Instructors:
Prof. Dr. Abdelwahed M. Assar
Dr Mahmoud M.Tash
e-mail: mahmoud_tash1@yahoo.com
A- Basic Information:
Title: Metal Casting
Code: MPD2108
nd
Year/Level 2 year Production Engineering and Mechanical Design
Credit Hours: 3 hrs lectures + 3 hrs tutorials
Total 6 hrs.
B- Professional Information
1. Aims:
Upon completion of the course the student should:
1. learn basics of metal casting
2. know the different types of sands used in casting
3. design patterns cores and molding
4. know the Principles of solidification,
5. understand the sand casting process
6. understand the foundry melting furnaces and calculate the charge in cupola
furnace
7. Conduct feeding and gating design calculations for simple parts, as well as
charge calculations for some important types of cast alloys.
8. know the basics of casting design
9. understand the metallurgy of casting (structure and properties)
10. know the different types of casting defects
11. understand other casting processes (permanent mould, die casting, shell
mould, investment casting, centrifugal and continuous casting)
12. Correlate the different casting parameters (molding conditions and melting
parameters) to the quality of the castings and to the basic metallurgical
concepts.
13. Be acquainted with cast alloys and use his information about engineering
alloys to understand the properties of cast alloys.
2. Intended Learning Outcomes (ILOs)
a. Knowledge and understanding
a.1Technology of sand casting.
a.2 Melting and furnaces.
a.3 Theory of solidification.
a.4 Cast alloys.
b. Intellectual skills
b.1Design of gating and feeding systems.
b.2 Choice of proper casting method for different products.
c. Professional and practical skills
c.1 How to design moulds and pattern for making castings
c.1 How to inspect a casting
d. General and transferable skills
d.1 Report writing.
d.2 Presentation skills.
3. Contents:
Introduction, Liquid metals, Fluid dynamics, Principles of solidification, alloyed
casting, sand casting (patterns, molding techniques, forces acting on flask, casting
equipments, cupola charge calculations, sands used in casting, pouring system, risers,
design of castings, structure and properties of castings, defects of sand castings) other
casting processes, quality control in cast processes.
Lecture Topic Outline
No. of hours
Week
Topics
Lect
Metal casting: Introduction, each student group will
make a presentation on one of the following topic:
1
-
melting furnaces -casting methods
-
casting defects.
Tutorial
3
3
2
Sand casting process: Types of sands used in casting
3
Sand casting process: Patterns, cores and molding
design
3
3
4
Sand casting process: Melting Furnaces- Charge
Calculations in cupola furnace. Problems on charge
calculations
5
Basics of casting design
6
Design Of Gating And Feeding Systems: Fluidity of
molten metal, gating system, design. Problems on
design of gating systems.
3
3
3
3
3
3
3
3
7
Design Of Gating And Feeding Systems: Solidification,
design of feeding system. Problems of design of
feeders.
8
Field Visit to a big foundry.
9
Mid Term Exam
3
3
10
Principles of Solidification, metallurgical aspect.
3
3
11
Metallurgy of casting: Structures and properties of
casting.
3
Casting defects and their correlation to manufacturing
parameters.
3
12
Other casting processes (permanent mould, die casting,
shell mould, investment casting, centrifugal and
continuous casting).
3
Quality control of metal casting, Inspection of casting
3
13
14
3
3
3
3
3
3
3
3
4. Teaching and learning methods and Aids:
Blackboard, Overhead Transparencies
5. Student Assessment and Grading Basis:
Attendance of lectures and tutorials is a most. Homework assignments will consist
of essay questions and problem solving cases. There will be two quizzes and one
midterm examinations and one final test. Examinations are comprehensive,
including subjects from all assigned readings, lectures, reports, and classroom
demonstrations.
Year Work:
Item
#Points%
Totals__
Attendance and Pop Quizzes
5
Reports and discussions
10
Homework assignments
10
Report on Field Studies
10
One midterm exams
25
60
Final Examination
90
____________________________________ _______150_____________________
6. List of References:
1- Fundementals of Metal Casting; R. A. Flinn, Addison-Wesley Publishing
Company, 1963.
2- Principles of Metal Casting; R. W. Heine, C. R. Loper, and P. Rosenthal, Mc.
Graw Hill Publishing Company, 1989.
3- Metal Casting, A. M. Mikhalof Mir Publishers, 1989.
4- Foundry Technology; K. P. Sinha and D. B. Goel, Standard Publishers
Distributors, 1978.
5- Principles of Foundry Technology; P. L. Jain, Tata Mc. Graw-Hill Publishing
Company, 1999.
6- Foundry Technology; P. R. Beeley; Butterworth-Heinemann, 2001.
7- Internet sites: ILSAP and AZOM.com