New Dates IndianInstituteofTechnologyBombay ContinuingEducationProgrammeforWorkingProfessionals October1113,2010 Science,Engineering,Technology,andApplication INTRODUCTION Is it possible to get quality castings by design?

y design? Can we develop them without shopfloor 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 theirdesign.Thedesiredpricequalityresponsecompetitivenesscanbeachievedwithoutwastingany timeandmanufacturingresourcesfortoolingmodificationandfoundrytrials.

CastingDesignandSimulation

STRUCTURE

The Casting Design and Simulation course, conducted every year since 2000, has benefitted several hundred working professionals. It comprises high quality lectures, exercises, and computeraided 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 ferrousandnonferrousmetalsarecovered. SessionTimings: 08:3017:30 1:Science Basicphysicsinvolvedinmetalcastingprocess:cavitycreation,filling,heattransfer 2:Engineering Applyingscientificprinciplesforperfectdesignofmold,feedingandgatingsystem 3:Technology Qualityandfrugalitybysimulation,LiveClinic,industrialcasestudies,future 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, butnotnecessary.Seniorexecutivesusuallyderive(andlaterdrive)morebenefits,including: Scientificapproachforcastingdesignapplicabletoindustrialparts Firsthandexposuretocastingmethodsdesignandsimulationsoftware Comprehensivecoursematerialforpersonalreferenceandpractice Industrialcasestudiesshowinghowtoimprovequalityandyield Rs.18,000 Rs.15,000 Foreignparticipants:US$500 (Coursematerialonly:Rs.3000)

SCHEDULE/DAY

BENEFITIARIES

COURSEFEES

Workingprofessionalsinindustry,R&D: TeachersandPGresearchstudents: Coursefeescoverthefollowing: 9 9 9 9

Coursematerial(printedslides,book,castingsoftwareandresourceCD) Participationinallsessionsandcomputertraining,withlunchandtea(3days) AccommodationinIIT/MTNLguesthouse(foroutofstateparticipants)for3nights Castingsimulation(forindustryparticipants),ifcastingmodelissentoneweekinadvance

ParticipantsmustmaketheirownarrangementsfortraveltoandfromIITBombay. REGISTRATION Interested participants may fill, scan and email their qualifications and experience (PartA of the registrationform)toCE&QIPoffice.Theywillbeselectedbasedonpotentialtoabsorbandimplement the technologies. After confirmation from IIT, the registration fees may be sent by a bank draft in favour of The Registrar, I.I.T. Bombay payable at Mumbai. Seats are limited (maximum two per organization),andwillbeallottedonafirstcomefirstservebasis. Mr.D.R.Joshi/Mrs.PradnyaPurohit CE&QIPOffice,I.I.T.Bombay,Mumbai400076 Mail:cep@iitb.ac.in,Phone:+912225767060/7047 Website:http://www.iitb.ac.in/~cep

CONTACT

Prof.B.Ravi(Coordinator) Email:efoundry.iitb@gmail.com Phone:+912225767510/4399 http://www.me.iitb.ac.in/~bravi/lab

COURSEMATERIAL

DETAILEDSCHEDULE
Mon,11Oct 08:3009:30 09:3010:30 10:3011:00 11:0012:00 12:0013:00 13:0014:00 14:0015:00 15:0016:00 16:0016:30 16:3017:30 Tue,12Oct 08:3009:30 09:3010:30 10:3011:00 11:0012:00 12:0013:00 13:0014:00 14:0015:00 15:0016:00 16:0016:30 16:3017:30 Wed,13Oct 08:3009:30 09:3010:30 10:3011:00 11:0012:00 12:0013:00 13:0014:00 14:0015:00 15:0016:00 16:0016:30 16:3017:30 ScienceStudyingthebasicphysicsinvolvedinmetalcastingprocess Welcome:coursekithandover;introductions ofparticipantsandorganizingteam;inauguration Courseoverview:goals,contents,coursematerials, pedagogy,exercisesanddemos,arrangements TeaBreak Castingindustry:statusandchallenges, anatomyofaperfectcasting qualitywithfrugality Moldgeometry:representation,transformations (parttoproduct),thickness,junctions,shapecomplexity LunchBreak Exercise:geometricpropertiesandcomplexityofabenchmarkcasting;Demo:3Dmodellingofcasting Metalfilling:metallostaticpressure,velocityandlosses,flowthroughchannels,fluidity,turbulence TeaBreak Castingsolidification:freezingrange,thermalgradients,coolingrate,shrinkage,microstructure Engineering Applyingscientificprinciplesforperfectcastingdesign Perfectmold:moldparting,pattern/diedesign,draftandallowances,cores,cavitylayout,moldability Perfectfeeders:feedingrequirement,feederlocation,shape,size,connection,feedaids,feedability TeaBreak Perfectgating:requirement,layout,fillingtime,gatingratio,choke,channeldesign,filters,fillability Castingsimulation:numericalmethods,boundaryconditions,moldfillingandsolidification,defectprediction LunchBreak Exercise:feederandgatingdesignforasimple casting;demo:computeraidedmethodsdesign Computertraining:partproperties,coredesign,moldcavitylayout, simulation,costing,methodsreport TeaBreak Labvisit:OrthoCADNetworkResearchCell(nearElectricalSubStation,IDCHillsideroad) Technology Achievingquality andfrugality bydesign&simulation Designforquality:partdesignguidelines;castabilitycriteriaandindex;designoptimization Designforfrugality:earlyestimationoftooling,materialandconversioncosts;costreductiontechniques TeaBreak Simulationclinic:troubleshootingofparticipants owncastingsforqualityoryieldimprovement Industrialcasestudies:bycastingsimulationusers(consultantsandfoundryengineers) LunchBreak Industrysurvey:computerapplicationsinIndianfoundryindustry;objectivetest(multiplechoicetype) Bestpractices:castingdesign,simulationandoptimization;speedandaccuracy;projectdatamanagement TeaBreak Conclusion:collaborationavenues,certificates,coursefeedback,voteofthanks.

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 doublesharing basis, and strictly for 3 days and 3 nights only. The arrival and departure details must be provided at least 10days in advance to IITs CEP office, to ensureconfirmed reservation. Participants wishing to staylongermustcheckforroomavailabilityandrates,andsettlethebillforadditionalstaydirectlywiththeguesthouse. Name IITGuesthouse MTNLGuesthouse ParadiseGuestHouse CHSGuestHouse Address JalVihar/VanVihar,IITBombay,Powai, Mumbai400076 CETTMHostel(MTNL), Main Street, HiranandaniGardens,Powai,Mumbai400076 ParadiseBldg.,Flats1&2,opp.IIT,Maingate, JainMandirMarg,Powai,Mumbai400076 NearCafeCoffeeDay,BesidesJheelDarshan Bldg.,Powai,Mumbai400076 Phone 02225768946, 25768945 02225704445 02225781092, 09833638355 09869443365 Distance 0km 2km 1km 3km

Vanviharguesthouseandduckpond

Simulationtrainingsessioninconferenceroom

ComputeraidedsurgerydemoinOrthoCADlab

PARTICIPANTSOFPREVIOUSCOURSES
2009:ArbariyaSteels,Agra;A.K.Multimatal,Gobindgarh;AdvikHiTech,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; 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; 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; CITChanga, Anand; DKTE Textile EnggInstitute,Ichalkaranji;VVPEnggCollege,Rajkot. 2008: AKP Foundries, Belgaum; Alstom Projects India, Shahabad; AMPRI, Bhopal; Ashok Iron Works,Belgaum;AtlasCopco(India),Nasik;BharatHeavyElectricals,Bhopal;BhawaniIndustries, 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; VSmart Thermotech, Pune; V.J.T.I., Mumbai; Warren Steels, 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; 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; NonFerrous Materials Tech. Dev. Centre, Hyderabad; Ordnance Factory,Ghaziabad;RizviCollegeofEngg.,Mumbai;andUVPatelCollegeofEngg.,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; KolhapurInstituteofTechnology,Kolhapur;Mahindra&Mahindra,Mumbai;MenonandMenon, Kolhapur; Moderncast, Bangalore; Nelcast, Gudur; Progressive Engineering, Mumbai; Philips India, Kolkata; Sai Founders and Engineers, Belgaum; Sriram Pistons, Ghaziabad; Supercastings, Thane;TechnocraftIndustries,Mumbai;TulsiFoundries,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; SynergiesDooray Automotive, Vizag; Tata Cummins, Jamshedpur; Tata Holset,Pune;TataTechnologies,Pune.

IjusthadafeelingofspacewalkinfoundrySuchknowledgeisnoteasilyavailableReallyinterestingandinspiring Itwasagreatlearning,themosteffectivetrainingIhadinmylifeExperienceofyearsputintoandcoveredindays

REGISTRATION FORM ContinuingEducationProgrammeon

CastingDesignandSimulation
I.I.T.Bombay,Mumbai,October1113,2010 (PLEASE STAPLE YOUR VISITING CARD HERE)

PARTA (Pre-registration)

Name: Mr./Ms. ________________________________________________________ Age: ___________ years Designation: Organisation: Address: Address: City: Phone: Fax: Category: ______________________________ Department: __________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ ______________________________ State: __________________ PIN: ________________ ( _________ ) __________________ Mobile: _______________________________________ ( _________ ) __________________ E-mail: _______________________________________ 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 ___________________________________________________________________
PARTB (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 Regn. Fees:

Current method layout sketch/drawing/image file Photo of casting section showing internal defect

Rs. 18,000 for industry participants, Rs. 15,000 for academic participants, US$ 500 for foreign participants (Noincometaxistobedeductedatsourcefromcoursefee,asIITBisexemptfromthesame).

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 15 AUGUST 2010

Ifaregisteredparticipantisunabletoattend,asuitablecolleaguecanbenominatedinstead(onlynewregistrationformtobesent) Cancellation:100%refundofregistrationfeesforrequestsreceivedupto30Sept2010:75%refundafter30Sept2010.