Manufacturing project – Group Project Report
MANUFACTURING OF A BRACKET BY METAL CASTING
(Total Marks: 25% Weightage)
Due date: 07-11-2024
Learning Outcomes:
1. Select and analyze appropriate mechanical engineering manufacturing processes for metal
components/assemblies to achieve required product specifications. Range includes casting,
forging, rolling, extrusion.
2. Design, process, evaluate and cost parameters for casting and metal forming applications
Problem Statement:
A Bracket with the following dimensions as shown in Figure 1, Table 1 and Table 2 must be
casted with the following stringent requirements.
The requirements for performance, casting production, and cost are taken into consideration.
Select an alloy that meets the mechanical requirements and reliably produces the castings
in a sound condition.
Select a molding method that produces the required dimensional tolerances and surface
finish in a cost-effective manner.
Develop a casting and mold design that produces flaw-free within-tolerance connectors
at the best cost.
GROUP 2
All Dimensions are in “mm”
Table: 1 Input Geometric parameters for the casting of BracketTable: 2 Input materials for the casting of BracketTask to be carried out with marking scheme
S.No
Tasks to be carried out
Max
Marks
LO’S
assessed
1
Selection of manufacturing process with valid considerations
05
LO1
2
Selection of material for casting with finalised mechanical
properties
05
LO1
3
Product design considerations (Various allowances)
10
LO2
4
Pouring and Gating calculations
10
LO2
5
Riser Design and Riser Position
15
LO2
6
Heating calculation, Selection & description of furnace for the
desired application
05
LO1
7
Pouring, cleaning and Finishing operation
10
LO1
8
Casting quality &Inspection required
10
LO1
9
✓ Complete three-dimensional model of the sand casting
(showing the pattern, cavity, runner, riser, gating etc.)
✓ Exploded View with BOM
✓ Engineering drawing of the moulding showing the
major dimensions
30
LO2
Total Marks: 100
✓ Submission: Each team leader of the GROUP should submit the project report as a pdf
file in MOODLE (Turnitin based)
✓ Include the screenshot of all the solid work drawings in the report.
✓ Refer class notes and standards for MOLD Design
✓ Assume suitable data and provide justification and evidence for assumption
✓ Mold design files (Solid works File) should be submitted as a Zip file in Moodle
submission
✓ Plagiarism policy will be strictly followed Detailed Marking for the Project
Total marks: 100
Design components
Maxim
um
marks
Assessment Criteria
Selection of manufacturing
process with valid
considerations
05
Selected stating all
considerations (5)
Selected stating some
considerations
(0-4)
Selection of material with
finalised mechanical
properties
05
Material selection
justified (5)
Material Selection not justified
perfectly (0-4)
Heating and Pouring
calculations
10
Calculations are
correct (09-10) with
the assumptions
stated clearly
Calculations are
correct (06-08)
with the
assumptions not
stated clearly
Calculations
are not
correct (0-06)
with the
assumptions
not stated
clearly
Riser Design and
Calculations
15
Calculations are
correct (14-15) with
the assumptions
stated clearly
Calculations are
correct (09-13)
with the
assumptions not
stated clearly
Calculations
are not
correct (0-08)
with the
assumptions
not stated
clearly
Product design
considerations (Various
allowances)
10
Considered all the
allowances in the
design of the mold
and reflected in the
drawing (9-10)
Not Considered
all the allowances
in the design of
the mold but
reflected in the
drawing
(07-8)
Not
Considered all
the
allowances in
the design of
the mold and
not reflected
in the
drawing(0-6)
Selection & description of
furnace for the desired
application
05
Selection and
description
provided exactly
(5)
Selection and description not
provided in detail (0-4)
Pouring ,cleaning and
Finishing operation
10
Discussed all the
machining
operations
Discussion not up
to the mark and
not followed
Discussion
not clear (0-5)(9-10)
sequence
(6-8)
Casting quality
10
Casting defects and
inspection
discussed
thoroughly (09-10)
Casting defects
and inspection
discussed but not
in detailed
manner
(06-08)
More scope
for
improvement
(0-05)
Model and Engineering
drawing
30
Drawing up to the
standard and
reveals all the
information (28-30)
Drawing not to
the standard and
with missing
information (15-
27)
Drawing is
not to the
standard and
provided with
less
information
(0-14)