INTRODUCTION Is it possible to get quality castings by design?

Canwedevelop themwithout shopfloor trials?Yes, ifwehaveagoodknowledgeofunderlyingscience, apply it to engineer good castings, andusesimulationtechnologytoverifyandoptimizetheirdesign.Thedesiredpricequalityresponsecompetitivenesscanbeachievedwithoutwastinganytimeandmanufacturingresourcesfortoolingmodificationandfoundrytrials.

STRUCTURE TheCastingDesignandSimulationcourse,conductedeveryyearsince2000,hasbenefittedseveralhundredworking professionals. It comprises high quality lectures, exercises, and computeraidedcastingdesignsession,reinforcedwithlivesimulationclinic.Participantsbringtheirproblemcastings(high rejections, lowyield) for insightandadvice.Sand, investmentandgravitydiecastingofbothferrousandnonferrousmetalsarecovered.

SCHEDULE/DAY SessionTimings:08:3017:301:Science Basicphysicsinvolvedinmetalcastingprocess:cavitycreation,filling,heattransfer2:Engineering Applyingscientificprinciplesforperfectdesignofmold,feedingandgatingsystem3:Technology Qualityandfrugalitybysimulation,LiveClinic,industrialcasestudies,future

BENEFITIARIES Thecourse isdesignedforfoundry,productandtoolingengineers,aswellasconsultants,teachers,andresearcherswithabasicknowledgeofmetalcasting.Priorexposure tocomputers isdesirable,butnotnecessary.Seniorexecutivesusuallyderive(andlaterdrive)morebenefits,including:

Scientificapproachforcastingdesignapplicabletoindustrialparts Firsthandexposuretocastingmethodsdesignandsimulationsoftware Comprehensivecoursematerialforpersonalreferenceandpractice Industrialcasestudiesshowinghowtoimprovequalityandyield

COURSEFEES Workingprofessionalsinindustry,R&D: Rs.18,000 Foreignparticipants:US$500TeachersandPGresearchstudents: Rs.15,000 (Coursematerialonly:Rs.3000)

Coursefeescoverthefollowing:

Coursematerial(printedslides,book,castingsoftwareandresourceCD) Participationinallsessionsandcomputertraining,withlunchandtea(3days) AccommodationinIIT/MTNLguesthouseforoutofstateparticipantsfor3nights Castingsimulationforindustryparticipants,if3DCADmodelissentinadvance

ParticipantsmustmaketheirownarrangementsfortraveltoandfromIITBombay.

REGISTRATION Interested participantsmay fill, scan and email their qualifications and experience (PartA of theregistrationform)toCE&QIPoffice.Theywillbeselectedbasedonpotentialtoabsorbandimplementthe technologies.Afterconfirmation from IIT, thecomplete formmaybesentalongwith feesbyabankdraftinfavourofTheRegistrar,I.I.T.BombaypayableatMumbai.Seatsarelimited,andwillbeallottedonafirstcomefirstservebasis.Theregistrationswillbeclosedon20thSeptember2010.

CONTACT Mr.D.R.Joshi/Mrs.PradnyaPurohit Prof.B.Ravi(Coordinator)CE&QIPOffice,I.I.T.Bombay,Mumbai400076 Email:efoundry.iitb@gmail.com

Mail:cep@iitb.ac.in,Phone:+912225767060/7047 Phone:+912225767510/4399 Website:http://www.iitb.ac.in/~cep http://www.me.iitb.ac.in/~bravi/lab

IndianInstituteofTechnologyBombayContinuingEducationProgrammeforWorkingProfessionals

October1113,2010

CCCaaassstttiiinnngggDDDeeesssiiigggnnnaaannndddSSSiiimmmuuulllaaatttiiiooonnnScience,Engineering,Technology,andApplication

NewDates

COURSEMATERIAL

DETAILEDSCHEDULE

Mon,11Oct ScienceStudyingthebasicphysicsinvolvedinmetalcastingprocess

08:3009:30 Welcome:coursekithandover;introductionsofparticipantsandorganizingteam;inauguration

09:3010:30 Courseoverview:goals,contents,coursematerials,pedagogy,exercisesanddemos,arrangements

10:3011:00 TeaBreak

11:0012:00 Castingindustry:statusandchallenges,anatomyofaperfectcasting qualitywithfrugality

12:0013:00 Moldgeometry:representation,transformations (parttoproduct),thickness,junctions,shapecomplexity

13:0014:00 LunchBreak

14:0015:00 Exercise:geometricpropertiesandcomplexityofabenchmarkcasting;Demo:3Dmodellingofcasting

15:0016:00 Metalfilling:metallostaticpressure,velocityandlosses,flowthroughchannels,fluidity,turbulence

16:0016:30 TeaBreak

16:3017:30 Castingsolidification:freezingrange,thermalgradients,coolingrate,shrinkage,microstructure

Tue,12Oct Engineering Applyingscientificprinciplesforperfectcastingdesign

08:3009:30 Perfectmold:moldparting,pattern/diedesign,draftandallowances,cores,cavitylayout,moldability

09:3010:30 Perfectfeeders:feedingrequirement,feederlocation,shape,size,connection,feedaids,feedability

10:3011:00 TeaBreak

11:0012:00 Perfectgating:requirement,layout,fillingtime,gatingratio,choke,channeldesign,filters,fillability

12:0013:00 Castingsimulation:numericalmethods,boundaryconditions,moldfillingandsolidification,defectprediction

13:0014:00 LunchBreak

14:0015:00 Exercise:feederandgatingdesignforasimplecasting;demo:computeraidedmethodsdesign

15:0016:00 Computertraining:partproperties,coredesign,moldcavitylayout,simulation,costing,methodsreport

16:0016:30 TeaBreak

16:3017:30 Labvisit:OrthoCADNetworkResearchCell(nearElectricalSubStation,IDCHillsideroad)

Wed,13Oct Technology Achievingquality andfrugality bydesign&simulation

08:3009:30 Designforquality:partdesignguidelines;castabilitycriteriaandindex;designoptimization

09:3010:30 Designforfrugality:earlyestimationoftooling,materialandconversioncosts;costreductiontechniques

10:3011:00 TeaBreak

11:0012:00 Simulationclinic:troubleshootingofparticipantsowncastingsforqualityoryieldimprovement

12:0013:00 Industrialcasestudies:bycastingsimulationusers(consultantsandfoundryengineers)

13:0014:00 LunchBreak

14:0015:00 Industrysurvey:computerapplicationsinIndianfoundryindustry;objectivetest(multiplechoicetype)

15:0016:00 Bestpractices:castingdesign,simulationandoptimization;speedandaccuracy;projectdatamanagement

16:0016:30 TeaBreak

16:3017:30 Conclusion:collaborationavenues,certificates,coursefeedback,voteofthanks.

ACCOMMODATIONOutstationparticipantswillbeprovidedaccommodation in IITguesthouse,orotherguesthouses inPowai,tominimizetheirtotalcosts.Theaccommodation isondoublesharingbasis,andstrictlyfor3daysand3nightsonly.Thearrivalanddeparturedetailsmustbeprovidedatleast10daysinadvancetoIITsCEPoffice,toensureconfirmedreservation.Participantswishingtostaylongermustcheckforroomavailabilityandrates,andsettlethebillforadditionalstaydirectlywiththeguesthouse.

Name Address Phone Distance

IITGuesthouseJalVihar/VanVihar,IITBombay,Powai,Mumbai400076

02225768946,25768945

0km

MTNLGuesthouseCETTMHostel(MTNL), Main Street,HiranandaniGardens,Powai,Mumbai400076

02225704445 2km

ParadiseGuestHouseParadiseBldg.,Flats1&2,opp.IIT,Maingate,JainMandirMarg,Powai,Mumbai400076

02225781092,09833638355

1km

CHSGuestHouseNearCafeCoffeeDay,BesidesJheelDarshanBldg.,Powai,Mumbai400076

09869443365 3km

Vanviharguesthouseandduckpond

Simulationtrainingsessioninconferenceroom

ComputeraidedsurgerydemoinOrthoCADlab

PARTICIPANTSOFPREVIOUSCOURSES2009:ArbariyaSteels,Agra;A.K.Multimatal,Gobindgarh;AdvikHiTech,Pune;Apantec,Mumbai;Arjay Alloys, Kolhapur; Bajaj Auto, Pune; Birla Accucast,Waluj; Blue Light Industries, Dubai;CrescentFoundry,Kolkata;CumminsTurboTech.,Pune;EicherMotors,Pithampur;EngineeringCollege, Aurangabad; Galvano Castings, Bangalore; Gosain Foundry& Engg.Works, Ludhiana;GreyductFoundryServices,Ambala;GrowellIndustries,Vadodara;GuindyMachineTools,Hosur;GWASF Quality Castings,Mangalore; L&T CASE, Pithampur;Mahindra &Mahindra,Mumbai;MMR,Mumbai; NFTDC, Hyderabad; Precicast, Gurgaon; S.S.A. Steel Casting, Ambala; SGSITS,Indore;ShendhurAlloysFoundry,Coimbatore;ShimpukadeMetals,Kolhapur;ShreeKedarMetalFoundries, Sangli; Super Craft Foundry, Sangli; Tyco Thermal Controls,Mumbai; Unique AutoAssemblies, Ichalkaranji; Varindra Industrial Corp., Ludhiana; CITChanga, Anand;DKTE TextileEnggInstitute,Ichalkaranji;VVPEnggCollege,Rajkot.

2008: AKP Foundries, Belgaum; Alstom Projects India, Shahabad; AMPRI, Bhopal; Ashok IronWorks,Belgaum;AtlasCopco(India),Nasik;BharatHeavyElectricals,Bhopal;BhawaniIndustries,Ajnali; DCM Engineering Products, Ropar; DKTE's Textile & Engg. Inst., Ichalkaranji; EatonIndustries, Pune; Endurance Technologies, Pune; Gabriel India Limited, Hosur; IntegraAutomation,Coimbatore; JadavpurUniversity,Kolkata; JajalSteel,Kolhapur;KirloskarBrothers,Sangli; Madras Engg Industries, Chennai; Mahindra & Mahindra, Nasik, Mumbai; MarvelousEngineers,Kolhapur;MenonandMenon,Kolhapur;MenonPistons,Kolhapur;NirmaInstituteofTechnology,Ahmedabad;Northen IndiaEnggCollege,NewDelhi;Secan Invescast,Coimbatore;SGSITS,Indore;ShahHitech,Jamshedpur;ShahPrecicast,Sangli;ShanthalaSpherocast,Shimoga;ShreeHansAlloys,Ahmedabad;SouthernAutoCastings,Chennai;SundaramClayton,Chennai;TataAutocompSystems,Pune;TCS,Bangalore;TataMotors,Pune;TrimurtiEnggTools,Sangli;TVSmotorLimited,Hosur;VSmartThermotech,Pune;V.J.T.I.,Mumbai;WarrenSteels,Kolkata;WesternRefraCast,Ahmedabad;WorldOfSteel,Mumbai.

2006: Anant Enterprises, Pune; Ashok Leyland, Ennore; Bhagwati Spherocast, Ahmedabad;Cooper Foundry, Satara; GWASF Quality Castings, Mangalore; Himcast, Goa; L&T Foundry,Kansbahal; Mohan ElectroCasting, Ghaziabad; PTC Industries, Lukhnow; Sriram Foundry,Kolhapur; Tata Metaliks, Kolkata; Tata Maval Foundry, Pune; Techno Rings, Shimoga; andTexmaco, Kolkata.OEM firms: Atlas Copco,Nashik; Bajaj Auto, Pune; Bosch Chassis Systems,Pune; GE Healthcare, Bangalore; GE Medical Systems, Bangalore; Jash Engineering, Indore;Leader Valves, Ram Nagar; PermanentMagnets,Mumbai; Semco Electric, Pune; Tara Ultimo(Jewellery),Mumbai;TataCummins,Jamshedpur;TVSMotors,Hosur;andUniversalEngineeringand Electrical, Coimbatore. Others: Bureau of Industrial Consultancy and Research, Pune;CADMAXSolutions,Kolhapur;ESI India,Bangalore;Maharashtra InstituteofTechnology,Pune;Naval Dockyard, Mumbai; NonFerrous Materials Tech. Dev.