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Cas t i n g D es i gn an d An al ys i s

B . R avi
Mechanical Engineer ing Depar tment I ndian I ns titute of T echnology, B ombay

© 2002 Pr of. B . Ravi, I I T B ombay
All r ights r es er ved. No par t of this publication may be r epr oduced in any mater ial for m (including photocopying or s tor ing in any medium by electr onic means ) without pr ior wr itten per mis s ion of the author .

It is primarily meant for product designers and casting engineers. and Prof. Srinivasan at the Indian Institute of Science. cores. criteria for their quantitative assessment. Ravi IIT Bombay March 2003 2 . They can work towards connecting the physics of the process with empirical studies based on observation. India. Mandyam N. or are difficult to fill and feed. and and and and The logical approach will appeal to casting researchers and software developers. Robert C. I sincerely hope that the book is interesting and useful to the readers. Prof.P r ef ace This book presents the theory of metal casting from a mechanical engineer’s perspective. indeed there is very little technical literature showing how to design process-friendly cast products. Morgantown. Computer based analysis of mold filling casting solidification is also covered to highlight the current state-of-the-art. can be significantly improved by minor changes to design without affecting their functionality. B. Bangalore. a systematic approach to their design. While foundry engineers have access to an overwhelming amount of experimental work carried out over the last hundred years. Thus foundry engineers continue to spend several months to develop a casting. Product designers are rarely concerned with manufacturing aspects. especially those who are exploring how to get the castings ‘right first time’. We describe the role requirements of each of the above elements. rejection levels are significant and the yield (which directly affects energy costs) is sub-optimal. I wish to acknowledge the influence of three gurus who have influenced my thoughts: Prof. The book has evolved gradually over the last ten years of researching. especially those working on research projects is acknowledged. Finally. The contribution of students. teaching and industrial case studies at IIT Bombay. Many castings that require expensive tooling. many results contradict each other. John Campbell at the University of Birmingham. USA. and evolve better and faster tools for casting design and analysis. The book aims to bridge the above gaps. with respect to parting. and are often inapplicable to industrial castings. It will also be useful to teachers and students in engineering colleges and polytechnics. The main focus is on casting design analysis. gating and feeding. UK. and would greatly appreciate their feedback. Creese at the West Virginia University.