Overview
Assessor: Date of Marking:
Grade/Mark: 25% of total grade (Group Project)
Assessment Cover Sheet
Course Title:
Comments:
Assessment Title
Programme Title:
Course Code
Group members name:
Group members ID:
Tutor:
Due Date: 07/11/2024 Date submitted:
Do not write below this line. For Polytechnic use only
Dr.Rejikumar, Mr Isa AlQubaiti, Mrs Mini Jose, Mrs DivyaRyali
By submitting this assessment for marking, either electronically or as hard copy, I confirm the following:
➢ 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
Manufacturing, Control &Environmental Sustainability
Environment &
Bachelor of Engineering Technology
Manufacturing Project (Casting-Group Project)
EN 7908
system
Transmission sytesmTransmission)
)
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.
in a sound condition.
finish in a cost-effective manner.
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
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)