Select a metallic car/automotive part that, you think, is manufactured by casting, and necessitates sectioning into...

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Select a metallic car/automotive part that, you think, is manufactured by casting, and necessitates sectioning into at least 3 sub-parts for appropriate solidification sequence purposes. 1. Provide a sketch or a drawing of the component including approximate dimensions. What type of metal was used? Why? 2. State why you think the part is made by casting, and why it needs to be sectioned into the number of sub-parts you choose for appropriate solidification. 3. Select a casting process to best make the part. What mold material would you use? Justify! 4. Sketch the physical set-up that you would use to make the part (two views). Determine important design considerations such as solidification time and sequence; sprue dimensions and position, position of risers if required; where major defects might occur, what you have included to prevent such defects, and limitations of the process. You should have at least three potential defect locations indicated. Justify your statements. 5. For your selected process, comment on the surface finish, dimensional tolerances, the microstructure, the strength of the part, and the minimum batch size for economic competitiveness. 6. Assuming that a few of your cast parts need to be milled for a highly complex application, indicate what tool material and parameters you would use and estimate the tool life. Note that previous experience indicates that the tool would fail after one minute if you use a cutting speed of 4000 m/min. Use the values as provided in the class notes without any unit conversion for tool life in minutes. Discuss any potential need for cutting fluids. Select a metallic car/automotive part that, you think, is manufactured by casting, and necessitates sectioning into at least 3 sub-parts for appropriate solidification sequence purposes. 1. Provide a sketch or a drawing of the component including approximate dimensions. What type of metal was used? Why? 2. State why you think the part is made by casting, and why it needs to be sectioned into the number of sub-parts you choose for appropriate solidification. 3. Select a casting process to best make the part. What mold material would you use? Justify! 4. Sketch the physical set-up that you would use to make the part (two views). Determine important design considerations such as solidification time and sequence; sprue dimensions and position, position of risers if required; where major defects might occur, what you have included to prevent such defects, and limitations of the process. You should have at least three potential defect locations indicated. Justify your statements. 5. For your selected process, comment on the surface finish, dimensional tolerances, the microstructure, the strength of the part, and the minimum batch size for economic competitiveness. 6. Assuming that a few of your cast parts need to be milled for a highly complex application, indicate what tool material and parameters you would use and estimate the tool life. Note that previous experience indicates that the tool would fail after one minute if you use a cutting speed of 4000 m/min. Use the values as provided in the class notes without any unit conversion for tool life in minutes. Discuss any potential need for cutting fluids.