This project is a manufacturing-type project where a final cast will be produced using the sand casting process including all the design considerations necessary to produce a sound cast.

• Working in teams of three students.
• Choose a component that can be produced by sand casting process using the available facilities in the cast shop at ME department at AUC.
• Check with the workshop to make sure that the cast dimensions will fit into the steel flask.
• Prepare a detailed design for the pattern that will produce the desired casting taking into consideration all the allowances such as shrinkage allowances, machining allowances, draft, etc.
• Make detailed calculations for the Riser design.
• Show all considerations and calculations that are required for a well-designed Gating system if possible.
• Consider the workshop for producing the pattern and gating system.
• Arrange with the workshop for a date to produce the final cast.
• Submit a progress report for the part design including necessary calculations by Nov 17th 2002.
• Submit a full detailed technical report that includes the following:

    1. Introduction
    2. Objective
    3. Review
    4. Component Design (progress report)
    5. Experimental procedure (casting steps)
    6. Results
    7. Discussion
    8. Conclusion
    9. The cast product should also be submitted along with the report on Nov. 24th 2002