Design and Development of Foundry In Air University, Islamabad
We are presenting you for the first time, complete setup of a Casting foundry in Air University, Islamabad. The whole project is divided in four phases. The first phase is the literature review, comparing and comprehending Foundry setups Internationally setups in Universities worldwide. Visiting all
2025-06-28 16:31:22 - Adil Khan
Design and Development of Foundry In Air University, Islamabad
Project Area of Specialization Mechanical EngineeringProject SummaryWe are presenting you for the first time, complete setup of a Casting foundry in Air University, Islamabad. The whole project is divided in four phases. The first phase is the literature review, comparing and comprehending Foundry setups Internationally setups in Universities worldwide. Visiting all well reputed Universities in twin cities along with the local Casting Centres in Islamabad and Rawalpindi. In second phase, the material availability for the development of the Gas Casting Setup will be checked and a complete Laboratory Layout and heat analysis will be done on professional designing software. Third phase will consist of construction of Casting/Foundry Setup to reach pouring temperatures of Aluminium, Pure Silver and Brass, with maximum temperature up to 1600°C to according to the designed plan. In fourth and final phase, the smooth functionality will be tested. By following all the phases, the final product will be able to make sample parts without exceeding the safety limits.
Project Objectives•To design and develop a fully operative and functional foundry shop/Casting facility for Air University (AU).
•To design the layout of the casting facility and estimate ventilation requirements using numerical simulations.
•To install and functionalize a furnace that can attain up to 1600° C temperature.
•To design and document appropriate experiments for teaching and demonstrating mold casting of ferrous and non-ferrous metals as part of Manufacturing Process course.
•To ensure that all applicable safety requirements of a foundry shop/Casting facility are available in the setup.
Project Implementation Method•Visits of all the foundries available in different Universities within twin cities.
•Data compilation for selecting the most suitable pit furnace and finalization of required specifications/equipment (Material, fuel, and technology etc.)
•Procurement of required material(s) and parts.
•Designing of the Casting Facility layout and estimation of ventilation requirements using numerical simulations.
•Pit Furnace building and layout of the Foundry setup.
•Ensuring that all applicable safety requirements of a foundry shop/Casting facility are available in the setup.
•Documentation of the experiments for teaching and demonstrating mold casting of Ferrous and Non-Ferrous metals as part of the Manufacturing Process course.
Benefits of the ProjectAs it is for the first time in Air University Islamabad to have a Casting Facility as before that there was no any facility. And all students of Mechanical engineering used to graduate without having experience of Casting of metal or shapes.
Recently Higher Education Commission (HEC) has made this mandatory for next batches from now on to have the experiments of Casting metals in University
There will be a report containing literature review and detailed feasibility study to establish a Casting center/ Foundry setup.
Then the Designing, simulating, process will start and lastly construction of a Furnace.
A proper layout for Casting Center/ Foundry in AU.A fully operative and functional Casting foundry for AU workshop, that can be used to perform mold casting of Aluminum, Silver and Brass with melting tempratures of 700 °C, 950°C and 1000 °C respectively.
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 69944 | |||
| Transport cost | Miscellaneous | 1 | 10000 | 10000 |
| Blower | Equipment | 1 | 5000 | 5000 |
| Molasses | Equipment | 1 | 2000 | 2000 |
| Gas Cylinder | Equipment | 1 | 8000 | 8000 |
| Moulds | Equipment | 1 | 5000 | 5000 |
| Crucible Rate | Equipment | 2 | 5000 | 10000 |
| Bricks | Equipment | 16 | 184 | 2944 |
| Burner | Equipment | 1 | 2000 | 2000 |
| Pipe Fittings | Equipment | 2 | 5000 | 10000 |
| Thermocouple, Lighting equipment, ceramic bowl, refractory cement | Equipment | 1 | 10000 | 10000 |
| Labor Cost | Equipment | 1 | 5000 | 5000 |