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

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P r ef ace
This book presents the theory of metal casting from a mechanical engineers perspective. It is primarily meant for product designers and casting engineers, especially those who are exploring how to get the castings right first time. Product designers are rarely concerned with manufacturing aspects; indeed there is very little technical literature showing how to design process-friendly cast products. Many castings that require expensive tooling, or are difficult to fill and feed, can be significantly improved by minor changes to design without affecting their functionality. While foundry engineers have access to an overwhelming amount of experimental work carried out over the last hundred years, many results contradict each other, and are often inapplicable to industrial castings. Thus foundry engineers continue to spend several months to develop a casting, rejection levels are significant and the yield (which directly affects energy costs) is sub-optimal. The book aims to bridge the above gaps. The main focus is on casting design analysis, with respect to parting, cores, gating and feeding. We describe the role requirements of each of the above elements, a systematic approach to their design, criteria for their quantitative assessment. Computer based analysis of mold filling casting solidification is also covered to highlight the current state-of-the-art. and and and and

The logical approach will appeal to casting researchers and software developers. They can work towards connecting the physics of the process with empirical studies based on observation, and evolve better and faster tools for casting design and analysis. It will also be useful to teachers and students in engineering colleges and polytechnics. The book has evolved gradually over the last ten years of researching, teaching and industrial case studies at IIT Bombay. The contribution of students, especially those working on research projects is acknowledged. Finally, I wish to acknowledge the influence of three gurus who have influenced my thoughts: Prof. Mandyam N. Srinivasan at the Indian Institute of Science, Bangalore, India; Prof. Robert C. Creese at the West Virginia University, Morgantown, USA; and Prof. John Campbell at the University of Birmingham, UK. I sincerely hope that the book is interesting and useful to the readers, and would greatly appreciate their feedback. B. Ravi IIT Bombay March 2003