Manufacturing Project (Casting-Group Project)

Assessment Title

Programme Title:

Manufacturing Project (Casting-Group Project)

Bachelor of Engineering Technology
EN 7908

Course Code

Course Title:

Manufacturing, Control &Environmental Sustainability

system

Environment &
Group members name:

Group members ID:

Transmission sytesmTransmission)
)

Dr.Rejikumar, Mr Isa AlQubaiti, Mrs Mini Jose, Mrs DivyaRyali

Tutor:

Due Date: 07/11/2024

Date submitted:

By submitting this assessment for marking, either electronically or as hard copy, I confirm the following:
➢
➢
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➢

This assignment is my own work
Any information used has been properly referenced.
I understand that a copy of my work may be used for moderation.
I have kept a copy of this assignment

Do not write below this line. For Polytechnic use only

Assessor:
Grade/Mark: 25% of total grade (Group Project)

Comments:

Date of Marking:

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.

Figure 1. Dimensions of Bracket
GROUP
NAME

A

B

C

D

E

F

GROUP 1

200

120

60

40

60

30

GROUP 2

220

130

70

50

70

40

GROUP 3

240

140

80

60

80

50

GROUP 4

260

150

90

70

90

60

GROUP 5

280

160

100

80

100

70

All Dimensions are in “mm”
Table: 1 Input Geometric parameters for the casting of Bracket

Table: 2 Input materials for the casting of Bracket

Task to be carried out with marking scheme

S.No

Tasks to be carried out

Max
Marks
05

LO’S
assessed
LO1

1

Selection of manufacturing process with valid considerations

2

05

LO1

3

Selection of material for casting with finalised mechanical
properties
Product design considerations (Various allowances)

10

LO2

4

Pouring and Gating calculations

10

LO2

5

Riser Design and Riser Position

15

LO2

6

05

LO1

7

Heating calculation, Selection & description of furnace for the
desired application
Pouring, cleaning and Finishing operation

10

LO1

8

Casting quality &Inspection required

10

LO1

✓ 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

9

✓ 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

Selection of manufacturing
process with valid
considerations
Selection of material with
finalised mechanical
properties
Heating and Pouring
calculations

05

Selected stating all
considerations (5)

05

Material selection
justified (5)

10

Calculations are
correct (09-10) with
the assumptions
stated clearly

Calculations are
correct (06-08)
with the
assumptions not
stated clearly

Discussed all the
machining
operations

Discussion not up
to the mark and
not followed

Riser Design and
Calculations

15

Product design
considerations (Various
allowances)

10

Selection & description of
furnace for the desired
application

05

Pouring ,cleaning and
Finishing operation

10

Assessment Criteria

Selected stating some
considerations
(0-4)
Material Selection not justified
perfectly (0-4)

Calculations
are not
correct (0-06)
with the
assumptions
not stated
clearly
Calculations are
Calculations are
Calculations
correct (14-15) with correct (09-13)
are not
the assumptions
with the
correct (0-08)
stated clearly
assumptions not
with the
stated clearly
assumptions
not stated
clearly
Considered all the
Not Considered
Not
allowances in the
all the allowances Considered all
design of the mold
in the design of
the
and reflected in the the mold but
allowances in
drawing (9-10)
reflected in the
the design of
drawing
the mold and
(07-8)
not reflected
in the
drawing(0-6)
Selection and
Selection and description not
description
provided in detail (0-4)
provided exactly
(5)
Discussion
not clear (0-5)

(9-10)
Casting quality

10

Casting defects and
inspection
discussed
thoroughly (09-10)

Model and Engineering
drawing

30

Drawing up to the
standard and
reveals all the
information (28-30)

sequence
(6-8)
Casting defects
and inspection
discussed but not
in detailed
manner
(06-08)
Drawing not to
the standard and
with missing
information (1527)

More scope
for
improvement
(0-05)

Drawing is
not to the
standard and
provided with
less
information
(0-14)

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