Dokuz Eylül University Information Package / Courses Catalog

Description of Individual Course Units

Course Unit Code	Course Unit Title	Type Of Course	D	U	L	ECTS
MMM 4048	CASTING DESIGN	ELECTIVE	2	2	0	4

Offered By

Metallurgical and Materials Engineering

Level of Course Unit

First Cycle Programmes (Bachelor's Degree)

Course Coordinator

PROFESSOR DOCTOR ÜMIT CÖCEN

Offered to

Metallurgical and Materials Engineering

Course Objective

Aim of the course is to give information about casting methods, pattern, core and mold design, risering and gating design, design for castability, charge calculations, and process planning and costing. Students are familiarized with simulation software. It is expected from students to be able to apply simulation studies to concerned subject given above and design casting for a particular part.

Learning Outcomes of the Course Unit

1	be able to conclude the factors/parameters affecting casting design,
2	be able to described material properties to be taken account for casting design,
3	be able to perform pattern and mold design by using simulation program on computer,
4	be able to perform simulation of solidification by using software on computer,
5	be able to discuss results obtained from simulation studies,
6	be able to determine stages and process flow chart of casting for a particular part,
7	be able to evaluate process design accordingly realistic criteria such as cost, environment, and etc., for a particular casting process.

Mode of Delivery

Face -to- Face

Prerequisites and Co-requisites

MMM 3008 - FOUNDRY TECHNOLOGY

Recomended Optional Programme Components

None

Course Contents

Week	Subject	Description
1	(Teo.) Introduction; typical flow charts for a sand foundry, molding and melting equipments, (App.) Introduction, solid modeling - Projects
2	(Teo.) Classifications of casting process, sand casting, permanent casting, die casting, investment casting, (App.) Formation of three dimensional modeling of casting and mold - Quiz 1
3	(Teo.) Patterns, Cores and molds (App.) Pattern, Core and mold design Homework 1
4	(Teo.) Pattern, Core and mold design (App.) Pattern, Core and mold design - Quiz 2
5	(Teo.) Solidification of metals and alloys (App.) Selection of casting alloy, molding and casting method - Homework 2
6	(Teo.) Solidification time and rate (App.) Determination of pouring temperature and solidification time - Quiz 3 Project report 1
7	Midterm exam 1 - Homework 3
8	(Teo.) Riser design and risering design optimization (App.)Risering design - Quiz 4
9	(Teo.) Mold Filling Phenomenon and Mold Filling simulation (App.) Risering design - Homework 4
10	(Teo.) Gating design (App.) Gating design - Quiz 5
11	(Teo.) Gating design optimization (App.) Gating design - Homework 5
12	Midterm exam 2 - Project report 2
13	(Teo.) Casting parameters optimization (App.) Determination of temperature distribution during filling and solidification and casting parameters optimization - Homework 6
14	Project presentation

Recomended or Required Reading

Instructors' course notes will be given during course.
1. Foundry Technology, Peter Beeley, Butterworth-Heinemann, ISBN 0-7506-4567-9, Ingiltere, 2001
2. Castings Practice: The Ten Rules of Castings, John Campbell, Elsevier Butterworth-Heinemann,, ISBN 07506 4791 4, Ingiltere, 2004
3. NovaCast simulation software.

Planned Learning Activities and Teaching Methods

Oral and visual lecture presentation, discussions, problem solving and writing paper and/or report.

Assessment Methods

SORTING NUMBER	SHORT CODE	LONG CODE	FORMULA
1	MTE1	MIDTERM EXAM 1
2	MTE2	MIDTERM EXAM 2
3	ASG	ASSIGNMENT
4	FIN	FINAL EXAM
5	FCG	FINAL COURSE GRADE	MTE1 * 0.10 + MTE2 * 0.10 + ASG * 0.30 + FIN * 0.50
6	RST	RESIT
7	FCGR	FINAL COURSE GRADE (RESIT)	MTE1 * 0.10 + MTE2 * 0.10 + ASG * 0.30 + RST * 0.50

*** Resit Exam is Not Administered in Institutions Where Resit is not Applicable.

Further Notes About Assessment Methods

Midterm exams, quizzes, and final exam will be performed as classical written exams with closed book-notebook. Assessment criteria and assignments related to homework and reports which requested from students, will be announced on the Web and linked from the department home page.

Assessment Criteria

Class participation, attendance and discussion, are important and expected, and will be included in overall evaluation. Learning outcome (LO3 to LO7) will be assessed by means of homework and project requested from students and also by means of exams. Learning outcomes (LO1 and LO2) will be assessed by means of exam questions.

Language of Instruction

Turkish

Course Policies and Rules

Students are expected to be in the classroom before the instructor s presence, not to interrupt the lecture, be prepared with the lecture material, as well as to contribute to scientific discussions during the lecture and to participate efficiently in every assignment. Lectures and examinations are carried out with respect to regulation of Engineering Faculty of Dokuz Eylul University, named "Principles of Education and Examination Practice".

Contact Details for the Lecturer(s)

Prof. Dr. Ümit CÖCEN
Metallurgical and Materials Engineering Department,
Floor:2 Room:288
phone: +90 (232) 301 74 58
e- mail: umit.cocen@deu.edu.tr

Assist. Prof. Dr. Bahadır UYULGAN
Metallurgical and Materials Engineering Department,
Floor:1 Room:200
phone: +90 (232) 301 74 69
e- mail: bahadir.uyulgan@deu.edu.tr

Office Hours

Fridays: 08:30-10:30

Work Placement(s)