To introduce students to the practice of
foam casting through casting student designed
part based on a theme intrduce in class.
To practice the identification of casting
defects.
To practice the safety and other rules
related to working in a foundry environment.
Assignment
Select:
a symbol. (final design
maybe an inspired interpretation of the original image)
The design constraints: Overall part
dimension: 3” x 3” [or if needed 3” x 4”] with an overall
height less than 6” including sprue. Layers: Three
distinct layers with at least two being of approximately
0.5” thickness Design theme: Pick a
symbol from the provided list Task:
Teams must submit a hand-drawn dimensioned rendering of the
selected symbol (listing all team members’ signatures) of
the intended design to the instructor in order to begin
work. Create: from Styrofoam the three
layered design (ideally each team member implements a layer)
Assemble the layers (including sprue) using glue gun Coat
assembled design with plaster of Paris in preperation for casting
the part using aluminum. Cast part:
using playground sand Remove: the cast part after it is cooled
from the sand. Cut: the attachments from the part, grind
and polish if necessary.
Lab Report
Your report should investigates
different aspects of the process that you performed in the
lab and provide extensive write up on areas such as cooling,
defects, and design.
Please make sure that you have read the lab work rules
and regulations before you start working in the lab. It is
important that you follow these instructions in order to
obtain the maximum points allowed for this assignment.
Compare the measurements of your finished product
with the pattern that you used and explain the
differences.
Discuss the defects that you observe in the finish
products and suggest methods to eliminate them.
Grading
Your grade for this assignment is a combination of some
general evaluation guidelines and some specific ones related
to this assignment.
General Guidelines
How well the team worked together
Whether the team members observed the safety rules,
and other rules as explained in the Lab Work document.
Whether the team progress was on a uniform basis or
most of the work was done at the end.
Whether the team followed the rules set for the lab
work or not.
The quality of the report, presentation, and
demonstration
Specific Guidelines
The quality and presentation of the research data.
Whether all team members were present during lab
experiment.
