Indian Institute of Technology Bombay Continuing Education Programme for Working Professionals

Transcription

1 Indian Institute of Technology Bombay Continuing Education Programme for Working Professionals October 11 13, 2010 Castiing Desiign and Siimullatiion Science, Engineering, Technology, and Application New Dates INTRODUCTION STRUCTURE Is it possible to get quality castings by design? Can we develop them without shop floor trials? Yes, if we have a good knowledge of underlying science, apply it to engineer good castings, and use simulation technology to verify and optimize their design. The desired price quality response competitiveness can be achieved without wasting any time and manufacturing resources for tooling modification and foundry trials. The Casting Design and Simulation course, conducted every year since 2000, has benefitted several hundred working professionals. It comprises high quality lectures, exercises, and computer aided casting design session, reinforced with live simulation clinic. Participants bring their problem castings (high rejections, low yield) for insight and advice. Sand, investment and gravity die casting of both ferrous and non ferrous metals are covered. SCHEDULE/DAY Session Timings: 08:30 17:30 1: Science Basic physics involved in metal casting process: cavity creation, filling, heat transfer 2: Engineering Applying scientific principles for perfect design of mold, feeding and gating system 3: Technology Quality and frugality by simulation, Live Clinic, industrial case studies, future BENEFITIARIES The course is designed for foundry, product and tooling engineers, as well as consultants, teachers, and researchers with a basic knowledge of metal casting. Prior exposure to computers is desirable, but not necessary. Senior executives usually derive (and later drive) more benefits, including: Scientific approach for casting design applicable to industrial parts First hand exposure to casting methods design and simulation software Comprehensive course material for personal reference and practice Industrial case studies showing how to improve quality and yield COURSE FEES Working professionals in industry, R&D: Rs. 18,000 Foreign participants: US$ 500 Teachers and PG research students: Rs. 15,000 (Course material only: Rs. 3000) Course fees cover the following: Course material (printed slides, book, casting software and resource CD) Participation in all sessions and computer training, with lunch and tea (3 days) Accommodation in IIT/MTNL guest house for out of state participants for 3 nights Casting simulation for industry participants, if 3D CAD model is sent in advance Participants must make their own arrangements for travel to and from IIT Bombay. REGISTRATION Interested participants may fill, scan and e mail their qualifications and experience (Part A of the registration form) to CE&QIP office. They will be selected based on potential to absorb and implement the technologies. After confirmation from IIT, the complete form may be sent along with fees by a bank draft in favour of The Registrar, I.I.T. Bombay payable at Mumbai. Seats are limited, and will be allotted on a first come first serve basis. The registrations will be closed on 20 th September CONTACT Mr. D.R. Joshi / Mrs. Pradnya Purohit Prof. B. Ravi (Coordinator) CE&QIP Office, I.I.T. Bombay, Mumbai E mail: efoundry.iitb@gmail.com Mail: cep@iitb.ac.in, Phone: / 7047 Phone: / 4399 Website:

2 COURSE MATERIAL DETAILED SCHEDULE Mon, 11 Oct Science Studying the basic physics involved in metal casting process 08:30 09:30 Welcome: course kit handover; introductions of participants and organizing team; inauguration 09:30 10:30 Course overview: goals, contents, course materials, pedagogy, exercises and demos, arrangements 11:00 12:00 Casting industry: status and challenges, anatomy of a perfect casting quality with frugality 12:00 13:00 Mold geometry: representation, transformations (part to product), thickness, junctions, shape complexity 14:00 15:00 Exercise: geometric properties and complexity of a benchmark casting; Demo: 3D modelling of casting 15:00 16:00 Metal filling: metallostatic pressure, velocity and losses, flow through channels, fluidity, turbulence 16:30 17:30 Casting solidification: freezing range, thermal gradients, cooling rate, shrinkage, microstructure Tue, 12 Oct Engineering Applying scientific principles for perfect casting design 08:30 09:30 Perfect mold: mold parting, pattern/die design, draft and allowances, cores, cavity layout, moldability 09:30 10:30 Perfect feeders: feeding requirement, feeder location, shape, size, connection, feedaids, feedability 11:00 12:00 Perfect gating: requirement, layout, filling time, gating ratio, choke, channel design, filters, fillability 12:00 13:00 Casting simulation: numerical methods, boundary conditions, mold filling and solidification, defect prediction 14:00 15:00 Exercise: feeder and gating design for a simple casting; demo: computer aided methods design 15:00 16:00 Computer training: part properties, core design, mold cavity layout, simulation, costing, methods report 16:30 17:30 Lab visit: OrthoCAD Network Research Cell (near Electrical Sub Station, IDC Hillside road) Wed, 13 Oct Technology Achieving quality and frugality by design & simulation 08:30 09:30 Design for quality: part design guidelines; castability criteria and index; design optimization 09:30 10:30 Design for frugality: early estimation of tooling, material and conversion costs; cost reduction techniques 11:00 12:00 Simulation clinic: troubleshooting of participants own castings for quality or yield improvement 12:00 13:00 Industrial case studies: by casting simulation users (consultants and foundry engineers) 14:00 15:00 Industry survey: computer applications in Indian foundry industry; objective test (multiple choice type) 15:00 16:00 Best practices: casting design, simulation and optimization; speed and accuracy; project data management 16:30 17:30 Conclusion: collaboration avenues, certificates, course feedback, vote of thanks.

3 ACCOMMODATION Outstation participants will be provided accommodation in IIT guest house, or other guest houses in Powai, to minimize their total costs. The accommodation is on double sharing basis, and strictly for 3 days and 3 nights only. The arrival and departure details must be provided at least 10 days in advance to IIT s CEP office, to ensure confirmed reservation. Participants wishing to stay longer must check for room availability and rates, and settle the bill for additional stay directly with the guest house. IIT Guest house Name Address Phone Distance MTNL Guest house Paradise Guest House CHS Guest House Jal Vihar/ Van Vihar, IIT Bombay, Powai, Mumbai CETTM Hostel (MTNL), Main Street, Hiranandani Gardens, Powai, Mumbai Paradise Bldg., Flats 1&2, opp. IIT, Main gate, Jain Mandir Marg, Powai, Mumbai Near Cafe Coffee Day, Besides Jheel Darshan Bldg., Powai, Mumbai , km km , km km Vanvihar guest house and duck pond Simulation training session in conference room Computer aided surgery demo in OrthoCAD lab

4 PARTICIPANTS OF PREVIOUS COURSES 2009: Arbariya Steels, Agra; A.K. Multimatal, Gobindgarh; Advik Hi Tech, Pune; Apantec, Mumbai; Arjay Alloys, Kolhapur; Bajaj Auto, Pune; Birla Accucast, Waluj; Blue Light Industries, Dubai; Crescent Foundry, Kolkata; Cummins Turbo Tech., Pune; Eicher Motors, Pithampur; Engineering College, Aurangabad; Galvano Castings, Bangalore; Gosain Foundry & Engg. Works, Ludhiana; Greyduct Foundry Services, Ambala; Growell Industries, Vadodara; Guindy Machine Tools, 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; Shendhur Alloys Foundry, Coimbatore; Shimpukade Metals, Kolhapur; Shree Kedar Metal Foundries, Sangli; Super Craft Foundry, Sangli; Tyco Thermal Controls, Mumbai; Unique Auto Assemblies, Ichalkaranji; Varindra Industrial Corp., Ludhiana; CIT Changa, Anand; DKTE Textile Engg Institute, Ichalkaranji; VVP Engg College, Rajkot. 2008: AKP Foundries, Belgaum; Alstom Projects India, Shahabad; AMPRI, Bhopal; Ashok Iron Works, Belgaum; Atlas Copco (India), Nasik; Bharat Heavy Electricals, Bhopal; Bhawani Industries, Ajnali; DCM Engineering Products, Ropar; DKTE's Textile & Engg. Inst., Ichalkaranji; Eaton Industries, Pune; Endurance Technologies, Pune; Gabriel India Limited, Hosur; Integra Automation, Coimbatore; Jadavpur University, Kolkata; Jajal Steel, Kolhapur; Kirloskar Brothers, Sangli; Madras Engg Industries, Chennai; Mahindra & Mahindra, Nasik, Mumbai; Marvelous Engineers, Kolhapur; Menon and Menon, Kolhapur; Menon Pistons, Kolhapur; Nirma Institute of Technology, Ahmedabad; Northen India Engg College, New Delhi; Secan Invescast, Coimbatore; SGSITS, Indore; Shah Hitech, Jamshedpur; Shah Precicast, Sangli; Shanthala Spherocast, Shimoga; Shree Hans Alloys, Ahmedabad; Southern Auto Castings, Chennai; Sundaram Clayton, Chennai; Tata Autocomp Systems, Pune; TCS, Bangalore; Tata Motors, Pune; Trimurti Engg Tools, Sangli; TVS motor Limited, Hosur; V Smart Thermotech, Pune; V.J.T.I., Mumbai; Warren Steels, Kolkata; Western Refra Cast, Ahmedabad; World Of Steel, 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 Electro Casting, Ghaziabad; PTC Industries, Lukhnow; Sriram Foundry, Kolhapur; Tata Metaliks, Kolkata; Tata Maval Foundry, Pune; Techno Rings, Shimoga; and Texmaco, 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; Permanent Magnets, Mumbai; Semco Electric, Pune; Tara Ultimo (Jewellery), Mumbai; Tata Cummins, Jamshedpur; TVS Motors, Hosur; and Universal Engineering and Electrical, Coimbatore. Others: Bureau of Industrial Consultancy and Research, Pune; CADMAX Solutions, Kolhapur; ESI India, Bangalore; Maharashtra Institute of Technology, Pune; Naval Dockyard, Mumbai; Non Ferrous Materials Tech. Dev. Centre, Hyderabad; Ordnance Factory, Ghaziabad; Rizvi College of Engg., Mumbai; and UV Patel College of Engg., Kherva. 2005: Anant Enterprises, Pune; Air Control and Chemical Engg, Ahmedabad; AKP Foundries, Belgaum; Alstom, Shahabad; Aurangabad Metal Products, Aurangabad; Ashok Iron Group, Belgaum; Atlas Copco, Nashik; Bharadia Steel, Mumbai; Central Institute of Tool Design, Hyderabad; DJS College of Engg, Mumbai; Defense Research and Development Lab, Hyderabad; Entek Corporation, Mumbai; Fine Jewellery, Mumbai; Foseco India, Pune; Gas Turbine Research Establishment, Bangalore; Govt. College of Engg, Karad; Indian Navy, Mumbai; Indo Danish Tool Room, Jamshedpur; John Deere India, Pune; JP Foundries, Belgaum; Kirloskar Brothers, Sangli; Kolhapur Institute of Technology, Kolhapur; Mahindra & Mahindra, Mumbai; Menon and Menon, Kolhapur; Moderncast, Bangalore; Nelcast, Gudur; Progressive Engineering, Mumbai; Philips India, Kolkata; Sai Founders and Engineers, Belgaum; Sriram Pistons, Ghaziabad; Supercastings, Thane; Technocraft Industries, Mumbai; Tulsi Foundries, Sangli. 2004: ACME Tools, Pune; Anant Enterprises, Pune; AFTC, Bangalore; BEL, Panchkula; Bhilai Engineering Corporation, Bhilai; CAL2CAL, Kolkata; Controllerate of Quality Assurance, Chennai; Crompton Greaves, Mumbai; Eicher Motors, Indore; I.I.T., Roorkee; Kirloskar Brothers, Dewas; Kirloskar Oil Engines, Pune; Laxmi Oil Pumps & Systems, Solapur; Mahalaxmi Auto Industries, Jamshedpur; Mahindra & Mahindra, Mumbai; MTAB Engineers, Chennai; Mutha Founders, Satara; National Institute of Foundry & Forge Technology, Ranchi; Parametric Technology, Bangalore; Prevail Casting, Rajkot; Pooja Engineers, Ahmedabad; FCR College of Engg., Mumbai; Shanthala Spherocast, Nidige; Silicon Meadows Design, Pune; Shree Ram Engineers, Mumbai; Swastik Metals, Jaipur; Synergies Dooray Automotive, Vizag; Tata Cummins, Jamshedpur; Tata Holset, Pune; Tata Technologies, Pune. I just had a feeling of space walk in foundry Such knowledge is not easily available Really interesting and inspiring It was a great learning, the most effective training I had in my life Experience of years put into and covered in days

5 REGISTRATION FORM Continuing Education Programme on Casting Design and Simulation I.I.T. Bombay, Mumbai, October 11 13, 2010 (PLEASE STAPLE YOUR VISITING CARD HERE) PART A (Pre-registration) Name: Mr./Ms. Age: years Designation: Organisation: Address: Address: City: Phone: Fax: Category: Department: State: PIN: ( ) Mobile: ( ) Industry: Foundry / OEM / Tool-room / Consultant / Other Academic: Faculty / Post Graduate Student Briefly describe your experience in metal casting (ex. methods design of steel castings) and computers: Metal casting Years: Computers Years: Reason to attend the course PART B (After confirmation) Enclosed Inputs for casting simulation clinic (from industry participants only): (These can be sent separately, but must reach us at least one week prior to the course) CD containing: Part model STL file (ASCII format) Photo of casting with risers, gates Current method layout sketch/drawing/image file Photo of casting section showing internal defect Regn. Fees: Rs. 18,000 for industry participants, Rs. 15,000 for academic participants, US$ 500 for foreign participants (No income tax is to be deducted at source from course fee, as IITB is exempt from the same). Bank draft no. Amount: Rs. Dated: Signature Date: PRINT/COPY THE FORM, COMPLETE (ONE FOR EACH PARTICIPANT), AND SEND ALONG WITH TOTAL PAYMENT, NOT LATER THAN 20 SEPT If a registered participant is unable to attend, a suitable colleague can be nominated instead (only new registration form to be sent). Cancellation: 100% refund of registration fees for requests received up to 30 Sept 2010: 75% refund after 30 Sept 2010.