Manufacturing project – Group Project Report MANUFACTURING OF A BRACKET BY METAL

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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)

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