Metal Casting Syllabus

Palestine Polytechnic University
(PPU)
College of Applied Professions
Department of Engineering Professions
Production and Machines (2016)

Course Outline: Metal Casting (MEP 224)
Spring 2017
Instructor:
Eng. Mahmoud Nassar (MSc.)
Time & Place:
Sunday, Tuesday, Thursday - 10:00 10:50, Building B+, Room # 002
Office hours:
Tuesday, 13:00 PM 14:00 PM
Tuesday, 10:00AM- 12:00 PM
or by appointment
Office:
Room # 315, Building C
Telephone:
Ext. 1312
Email:
[email protected]
1. COURSE DESCRIPTION:
This course is a requirement subject for production and machines
students. The course seeks to impart a coherent view of metal casting and
how they are modeled. It covers bigger spectrum for manufacture
products by the casting techniques with require attributes specify for
certain issues such as solidification, molding material, casting design,
production techniques and others. Among topics include in this course are
Metal melting & treatment, and casting quality & evaluation. In the second
part casting models, will be developed and applied in the context of
casting operations.
2. REQUIRED BACKGROUND OR EXPERIENCE:
Basic Manufacturing Processes.
3. TEXTBOOK & SUPPLEMENTAL MATERIALS:
The material covered will rely on class notes. Some of the seminar
papers in the modeling and development of microstructure will be
assigned for in-depth study and later presentation to the class.
Textbook (s):
1. Fundamentals of Metal casting, Flynn, Addison Wesley.
2. Product Design and Process Engineering Practice, Niebel & Draper,
Salmon & Simons, McGraw Hill Foundry, Issac Pitaman.
Supplemental Materials:
Notes will be handed out to the students on the topics and issues
which are not adequately discussed in the text book.
Reading Material
Will be given accordingly.
4. COURSE OBJECTIVES
The overall course objective is to train our students to be an innovator, an
entrepreneur
and finally, a manager by offering a combination of knowledge and
practical experience.
The course leads students through the process of creating, growing,
and managing a
venture. While working in teams, students can build leadership,
entrepreneurial skills,
and managerial skills. The team generates, evaluates, develops, and
markets their idea
(product, service, changeetc). The faculty member monitors, helps,
and advices
towards a final valid doable idea based on the concept sell a simpler
life. The team
generates, evaluates, develops, and markets their idea (product,
service, changeetc).
The faculty member monitors, helps, and advices towards a final valid
doable idea based
on the concept sell a simpler life.
(Correlate to the program objectives)
To provide students with a coherent knowledge of the

microstructures forming during the casting of metals
To enable students to model metal casting at the microscopic and
macroscopic scales while understanding the inherent limitations of
different models
To enable the students to apply their knowledge to the simulation of
metal casting operations to improve mold design and minimize
casting defects.
5. LEARNING OUTCOMES:
Outcome 1 (Correlated to Course Objective 1):
Student will be able to describe the types of microstructure present in a

casting given a material and a heat transfer rate
Student will be able to determine the effects of heat transfer,

temperature on the development of microstructures within a cast
Students will be able to solve and interpret casting problem using

Fluent.
Students will be able to write a program to that implements a variety

casting models
Students will be able to use visualization techniques to present and

interpret the numerical solution.
Students will be able to predicts some casting defects based on a

numerical solution.
6. RESOURCES AVAILABLE TO STUDENTS:
Class handouts, presentations, and auxiliary materials will be posted on
classroom & Facebook group.
Classroom: Metal Casting, Class Code: ukw3e5
Facebook Group Link: https://www.facebook.com/groups/PMECAP/
7. COURSE OUTLINE & DETAIL:

A: Assignment, Q: Quiz, M.T.: Midterm, C.S.: Case Study, RP:
Research Project.
Remarks
Hr.
Topic
A1
Introduction: The features of casting problem; a survey

and scope of foundry industry.
Solidification: Solidification of pure metals and al1oys;

nucleation and growth in alloys; solidification of actual
castings; progressive and directional solidification;
centerline feeding resistance; rate of solidification;
Chvorinov's Rule, electrical analog of solidification
problem.
Risering: Riser design; risering curves; NRL method of

riser design; feeding distance; risering of complex
casting; risering of alloy other than steel; recent
developments e.g. riser design by the application of
geometrical programming.
Q1
A2
Q2
Gating: Gating systems and their characteristics; the

effects of gates on aspiration; turbulence and dross trap;
recent trends.
Date W
22/01/201
7
24/01/201
1
7
26/01/201
7
29/01/201
7
31/01/201
2
7
02/02/201
7
05/02/201
7
07/02/201
7 3
09/02/201
7
12/02/201
7
14/02/201
7
16/02/201
7
C.S 1
Q3
Patterns: Pattern design; recent developments in pattern

design; materials and construction.
Molding and Core Making Processes: Review and

critical comparison of various established processes;
recent developments e.g. low pressure and ferrous die
casting; high pressure molding; full mold process;
flaskless molding, hot and cold box molding; ceramic
shell molding; V-process; continuous casting; squeeze
and pressed casting; Nishiyama process; Shaw process;
Anitoch process etc.
Melting: Selection and control of melting furnaces;
moiling, refining and pouring; recent trends in cupola
design.
Fluidity: Measurement of fluidity; effects of various

parameters on fluidity.
Midterm
(16/03)
A3
Internal Stresses, Defects and Surface Finish: Residual

stresses; hot tears and cracks in castings; stress relief;
defects and their causes and remedies; various
parameters affecting surface finish and related defects
e.g. rough Casting, sand bumon sand bumin and metal
penetration; facing and washes; mold wall movement;
vapor transpol1 zones; expansion scabbing etc.
Testing of Sand: Recent developments e.g. mulling
index; moldability index; compactability; deformability.
Q4
Casting Design Considerations: Review of casting

design; recent trends.
C.S. 2
A4
Gases in Metal: Methods of elimination and control of

dissolved gases in castings.
19/02/201
7
21/02/201
7
23/02/201
7
26/02/201
7
28/02/201
7
02/03/201
7
05/03/201
7
07/03/201
7
09/03/201
7
12/03/201
7
14/03/201
7
16/03/201
7
19/03/201
7
21/03/201
7
23/03/201
7
26/03/201
7
28/03/201 1
7 0
30/03/201
7
02/04/201
7
04/04/201
11
7
06/04/201
7
09/04/201 1
7 2
11/04/2017
Q5
Inspection and Quality Control: Review of X-ray and

gamma ray radiography; magnetic particle; penetrant
and ultrasonic inspections; use of statistical quality
control in foundry.
Project
Submissio
n
Revisions
13/04/201
7
16/04/201
7
18/04/201
7
20/04/201
7
23/04/201
7
25/04/201
7
27/04/201
7
1
3
1
4
8. ASSESSMENT AND EVALUATION

The course grade will be a composite of several measures, including
class participation (in-class exercises, presentations of reading material),
examination and a research component.
10 %
5%
5%
25 %
5%
10 %
40 %
100 %
Quizzes
Assignments
Case Studies
Midterm
Student Performance
Research Project
Final Exam
Total
9. ACADEMIC INTEGRITY:
The PPU catalog defines various forms of academic dishonesty and
procedures for responding to them. All forms are violations of the trust
between students and teachers. Students should familiarize themselves
with the penalties for plagiarism and other forms of cheating.
10.
STUDENT RESPONSIBILITIES
Minimum Student Materials

Text book and class handouts.
Collaboration Policies:
You can consult each other while working on the homework, but all
the work that you submit must be your own.
There will be group homework also. Furthermore, the capstone

project will be done in groups. Discuss the assignment among yourselves.
This is helpful to the learning process. However, direct copying of others
work will NOT be allowed or tolerated and will result in a reduction of
grade.
11.
COURSE POLICIES:
Students are encouraged to attend all classes. In case of absence from

any class, students are required to cover the missed material and inquire
about any announcements made during their absence. Students who miss
more than one fifth of class sessions are liable to be dropped from the
course.
No exam make-ups will be given. If the reason for missing the exam is
deemed acceptable the grades percentage of the missed exam will be
distributed amongst the other course graded activities
Each student is expected to read the assignment material and submit
assignment on due dates
Note:
Late assignments will not be accepted

If a student was to participate in an event outside of the class
scope, he/she must get a prior approval from the course instructor.
Student will not allow entering the classroom if late by more than 10
mins, unless there is strong reason for the delay.
12.
CODE OF ETHICS
Academic misconduct is defined as the use of any dishonest or deceitful to

gain some academic advantage or benefit. This can take many forms,
including but not limited to the following:
Examinations
Copying, or attempting to copy, from another students work, or

permitting another student to copy from your work.
Using notes of whatever kind in the formation of answers in a
closed book examination.
Impersonation of another student in an examination, seminar or
other form of presentation.
Disrupting the conduct of examinations by illegally obtaining
access to examination papers or answer, and/or distribution of
this material to others.
Assignments, Essays, etc.

Plagiarism: using the words, thoughts, ideas, results, etc., of another
person in a written assignment, without acknowledging the source, as if it
were the students own work.
Copying: copying another persons answers in an essay, assignment,

paper, laboratory report, etc., and presenting it, either wholly or with only
minor changes, as if it were the students own work.
Collusion: working with others on an assignment which is intended to be
an individual assignment, and incorporating their material into your work.
Switching: submitting work completed for one course in another course
without the permission of the instructor.
Falsification: inventing data or altering data that have been obtained
from legitimate sources.
Forging University Documents
Submitting or using forged academic documents or forged signatures
for the purpose of personal gain or fraud. If the student commits an act of
academic misconduct, whether defined above or of a different nature, it
may be documented and then one or more of the following penalties may
be applied:
13.
Written warning.
Downgrading of an assignment or examination.
An F grade given to the assignment or examination.
An F grade given to the course.
Suspension from the University for a Specified period.
Expulsion from the University.
IMPACT OF THE COURSE
This course is aimed at achieving the following professional
components:
To study and/or develop small scale new business venture.
To develop skills and commitment for engaging in life-long
learning skills.
To
develop
effective
communication
skills
and
work
independently as well as in a team on projects.
To understand business principles.

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Palestine Polytechnic University

Production and Machines (2016)

(Correlate to the program objectives)

To provide students with a coherent knowledge of the

Outcome 1 (Correlated to Course Objective 1):

Student will be able to describe the types of microstructure present in a

Outcome 2 (Correlated to Course Objective 1):

Student will be able to determine the effects of heat transfer,

Outcome 3 (Correlated to Course Objective 2):

Students will be able to solve and interpret casting problem using

Outcome 4 (Correlated to Course Objective 2):

Students will be able to write a program to that implements a variety

Outcome 5 (Correlated to Course Objective 3):

Students will be able to use visualization techniques to present and

Outcome 6 (Correlated to Course Objective 3):

Students will be able to predicts some casting defects based on a

7. COURSE OUTLINE & DETAIL:

Introduction: The features of casting problem; a survey

Solidification: Solidification of pure metals and al1oys;

Risering: Riser design; risering curves; NRL method of

Gating: Gating systems and their characteristics; the

Patterns: Pattern design; recent developments in pattern

Molding and Core Making Processes: Review and

Fluidity: Measurement of fluidity; effects of various

Internal Stresses, Defects and Surface Finish: Residual

Casting Design Considerations: Review of casting

Gases in Metal: Methods of elimination and control of

Inspection and Quality Control: Review of X-ray and

8. ASSESSMENT AND EVALUATION

Minimum Student Materials

There will be group homework also. Furthermore, the capstone

Students are encouraged to attend all classes. In case of absence from

Late assignments will not be accepted

Academic misconduct is defined as the use of any dishonest or deceitful to

Copying, or attempting to copy, from another students work, or

Assignments, Essays, etc.

Copying: copying another persons answers in an essay, assignment,

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