ME MP Lab Manual1-Merged

INSTITUTE OF AERONAUTICAL ENGINEERING
(Autonomous)
Dundigal, Hyderabad - 500 043
Lab Manual:
MANUFACTURING PROCESSES LABORATORY (AMEB06)
Prepared by
Dr. Ch.Sandeep (IARE10635)
DEPARTMENT OF AERONAUTICAL ENGINEERING

INSTITUTE OF AERONAUTICAL ENGINEERING
March 10, 2022
Contents
Content iv
1 INTRODUCTION 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 Student Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.2 Responsibilities of Faculty Teaching the Lab Course . . . . . . . . . . . . . 1
1.1.3 Laboratory In-charge Responsibilities . . . . . . . . . . . . . . . . . . . . . . 2
1.1.4 Course Coordinator Responsibilities . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Lab Policy and Grading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Course Goals and Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Use of Laboratory Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4.1 Instrument Protection Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Data Recording and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5.1 The Laboratory Worksheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5.2 The Laboratory Files/Reports . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 LAB-1 ARC WELDING (V-BUTT JOINT) 4

2.1 AIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 APPARATUS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 MATERIAL REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7 Pre Lab Viva Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.8 Post Lab Viva Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 LAB-2 ARC WELDING (LAP JOINT) 10

3.1 AIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 LAB-3 SPOT WELDING (LAP JOINT) 14

4.1 AIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.4 THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.5 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.6 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
i
5 LAB-4 TUNGSTEN INERT GAS (TIG) WELDING 18

5.1 AIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.4 THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.5 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.6 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6 LAB-5 PATTERN DESIGN AND MAKING 22

6.1 AIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.4 THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.5 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.6 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7 LAB-6 PATTERN DESIGN AND MAKING 27

7.1 AIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.4 THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.5 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.6 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8 LAB-7 SAND PROPERTIES TESTING 33

8.1 AIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.2 TOOLS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.5 THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.6 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9 LAB-8 CASTING FOR A SOLID PATTERN 36

9.1 AIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.4 THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.5 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.6 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
ii
10 LAB-9 CASTING FOR A SPLIT PATTERN 42
10.1 AIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10.4 THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10.5 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10.6 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11 LAB-10 STUDY OF PROGRESSIVE DIE 48

11.1 AIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.5 THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.6 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
11.7 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
12 LAB-11 STUDY OF COMPOUND DIE 56

12.1 AIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
12.4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
12.5 THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
12.6 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
12.7 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
13 LAB-12 DRAWING AND BENDING 63

13.1 AIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
13.2 EQUIPMENT AND TOOLS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . 63
13.4 THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
13.5 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
14 LAB-13 INJECTION MOULDING (AIR TIGHT BOTTLE CAP) 70

14.1 AIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
14.2 EQUIPMENT AND TOOLS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . 70
14.4 THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
14.5 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
14.6 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
15 LAB-14 PLASMA ARC WELDING 75
iii
15.1 AIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
15.2 Apparatus required: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
15.3 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
15.4 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
iv
INTRODUCTION
1.1 Introduction
This course is intended to enhance the learning experience of the student in topics encountered
in Manufacturing Processes (AMEC11) Course .In this lab, students are expected to develop
the practical skills required to do the experiments and gain experience in using the tools and
processes used in Mechanical Engineering. Students also learn to interpret the experimental
results in terms of the concepts introduced in the Manufacturing Processes course. How the
student performs in the lab depends on his/her preparation and participation. Each student
must participate in all aspectsof the lab to ensure a thorough understanding of the equipment
and concepts. The student, Faculty teaching the lab course, Laboratory In-charge and faculty
coordinator all have certain responsibilities towards successful completion of the lab’s goals and
objectives.
1.1.1 Student Responsibilities

The student is expected to come prepared for each lab. Lab preparation includes understanding
the lab experiment from the lab manual and reading the related textbook material.
Students have to write the allotted experiment for that particular week in the work sheets
given and carry them to the Lab. In case of any questions or problems with the preparation,
students can contact the Faculty Teaching the Lab course, but in a timely manner.
Students have to be in formal dress code, wear shoes and lab coat for the Laboratory Class.
After the demonstration of experiment by the faculty, student has to perform the experiment
individually. They have to note down the observations in the observation Tables drawn in work
sheets, do the calculations and analyze the results.
Active participation by each student in lab activities is expected. The student is expected
to ask the Faculty any questions they may have related to the experiment.
The student should remain alert and use commonsense while performing the lab experi-
ment.They are also responsible for keeping a professional and accurate record of the labexperi-
ments in the files provided.
1.1.2 Responsibilities of Faculty Teaching the Lab Course

The Faculty shall be completely familiar with each labprior to the laboratory. He/She shall pro-
vide the students with details regarding the syllabus and safety review during the first week.Lab
experiments should be checked in advance to make sure that everything is in working order.The
Faculty should demonstrate and explain the experiment and answer any questions posed by the
students.Faculty have to supervise the students while they perform the lab experiments. The
Faculty is expected to evaluate the lab worksheets and grade them based on their practical skills
and understanding of the experiment by taking Viva Voce. Evaluation of work sheets has to
be done in a fair and timely manner to enable the students, for uploading them online through
their CMS login within the stipulated time.
1
1.1.3 Laboratory In-charge Responsibilities
The Laboratory In-charge should ensure that the laboratory is properly equipped, i.e., the
Faculty teaching the lab receive any equipment/components necessary to perform the experi-
ments.He/She is responsible for ensuring that all the necessary equipment for the lab is available
and in working condition. The Laboratory In-charge is responsible for resolving any problems
that are identified by the teaching Faculty or the students.
1.1.4 Course Coordinator Responsibilities

The course coordinator is responsible fo rmaking any necessary corrections in Course Description
and lab manual. He/She has to ensure that it is continually updated and available to the students
in the CMS learning Portal.
1.2 Lab Policy and Grading

The student should understand the following policy:
ATTENDANCE: Attendance is mandatory as per the academic regulations.
LAB RECORD’s: The student must:
1. Write the work sheets for the allotted experiment and keep them ready before the beginning
of eachlab.
2. Keep all work in preparation of and obtained during lab.
3. Perform the experiment and record the observations in the worksheets.
4. Analyze the resultsand get the work sheets evaluated by the Faculty.
5. Upload the evaluated reports online from CMS LOGIN within the stipulated time.
Grading Policy:
The final grade of this course is awarded using the criterion detailed in the academic regula-
tions. A large portion of the student’s grade is determined in the comprehensive final exam of
the Laboratory course (SEE PRACTICALS),resulting in a requirement of understanding the
concepts and procedure of each lab experiment for successful completion of the lab course.
Pre-Requistes and Co-Requisties:

The lab course is to be taken during the same semester as AMEC11, but receives a separate
grade. Students are required to have completed both AMEC11 and AMEC15 with minimum
passing grade or better grade in each.
1.3 Course Goals and Objectives

The Manufacturing processes Laboratory course is designed as a foundation course to provide
the student with the knowledge to understand the basic concepts in Manufacturing processes
which have lot of applications in the field of Engineering.
The experiments are designed to complement the concepts introduced in AHSC03. In addi-
tion, the student should learn how to record experimental results effectively and present these
2
results in a written report.
More explicitly, the class objectives are:
1. Understand the Pattern design and making, casting drawing.
2. Utilize and determination of Sand properties testing for strengths and permeability
3. Demonstrate practical understanding Moulding,melting and casting
4. Demonstrate practical understanding of ARC welding lap and butt joint
5. Demonstrate practical understanding of Spotwelding, TIG welding
6. Demonstrate practical understanding of brazing
7. Understand Blanking and piercing, operation and study of simple, compound and progres-
sive press tool.
8. Demonstrate practical understanding of Hydraulic press, deep drawing and extrusion op-
eration.
9. Understand the Bending and other operation
10. Demonstrate practical understanding Injection moulding process
11. Demonstrate practical understanding Blow moulding process
12. Demonstrate practical understanding MIG welding exercises and Riveting of plates.
1.4 Use of Laboratory Instruments

One of the major goals of this lab is to familiarize the student with the proper equipment
andtechniques for conducting experiments. Some understanding of the lab instruments is neces-
saryto avoid personal or equipment damage.By understanding the device’s purpose and following
a fewsimple rules, costly mistakes can be avoided.
The following rules provide a guideline for instrument protection.
1.4.1 Instrument Protection Rules
1.5 Data Recording and Reports

1.5.1 The Laboratory Worksheets
1.5.2 The Laboratory Files/Reports
3
LAB-1 ARC WELDING (V-BUTT JOINT)
2.1 AIM
Prepare a V – Butt Joint using Arc Welding Process
2.2 APPARATUS REQUIRED

Wire Brush, Grinding Machine, Protective Equipment,
Welding Transformer, Electrodes, Tong, Chipping Hammer
2.3 MATERIAL REQUIRED

Mild steel flat of 60 x45 x 10 mm3 – 2 No s.
2.4 THEORY
Definition: Electric arc welding is “a welding process where in coalescence is produced by
heating with an arc or arcs, with or without the application of pressure and with or without
the use of filler metals”. Electric arc welding is quite versatile and able to weld under many
conditions. High quality welds are produced. Metal is deposited rapidly and it is competitive
cost wise for many situations.
Electric arc welding is the most extensively used method of joining components of metallic
parts, the source of heat being an electric arc. An electric arc is a continuous stream of electrons
flowing trough some sort of medium between two conductors of an electric circuit and accom-
panied by intense heat generation and radiation.
An electric arc for welding is obtained in the following ways:

1. 1. Between a consumable electrode (which also supplies filler metal) and the work piece.
2. Between a non consumable electrode (carbon, graphite or tungsten etc.) and the work
piece.
3. Between two non-consumable electrodes
The most common electric arc welding method is the one in which the arc is struck between an
electrode and the work. This is called as Direct arc. The arc struck between two non consum-
able electrodes adjacent to the parts being welded is called as Independent or Indirect arc.
The metal is heated by the indirect action (by radiation) of the arc. Due to this, the thermal
efficiency of the method is poor.
To strike an arc, the electrode is brought in contact with the work at the point where the weld-
ing is to be started, after connecting the work to the welding circuit. After a light contact, the
electrode is immediately withdrawn to a distance of from 2 to 4 mm from the work. Only a
4
comparatively low potential difference is required between the electrode and the work to strike
an arc. From 40 to 45 V is usually sufficient for D.C. and from 50 to 60 V for A.C. This voltage
available at the output terminals of a welding set, before the arc is struck, is known as open
circuit voltage (OCV). The voltage falls after the arc is established this is normally less than half
the OCV. A stable arc can be maintained between a metal electrode and the work metal with a
voltage of 15 to 30 V while from 30 to 35V is needed to strike an arc between non consumable
electrode and the work.
The stable arc required for high quality welding can be achieved with an arc length equal to 0.6
to 0.8 of the electrode diameter. The arc length is defined as the distance between the end of
the electrode and the surface of the molten metal on the work. When the electrode first makes
contact with the job, a large short circuit current flows. When the electrode later is immediately
withdrawn, the current continues to flow in the form of spark across the air gap so formed. Due
to this, the air gap gets ionized, that is, splits into electrons and positive ions. The lighter
electrons flow from cathode to anode and the heavier positive ions flow from anode to cathode.
Thus, the air gap becomes conducting and current is able to flow across the gap in the form of
an arc.
Electric Arc Welding
When the lighter, high-velocity electrons strike the anode at great velocity, intense heat is
generated at the anode. Heat generated at the cathode is much less, because of the low velocity
of impinging positive ions. Thermal and luminous energy is not uniformly evolved in the welding
arc. About 43 percent of the total amount of heat is evolved on the anode and about 36 percent
on the cathode. The remaining 21 per cent is evolved by the arc.
The temperature of an electric arc depends upon the type of electrodes between which it is
struck. It is about 32000 C on the cathode and about 39000 C on the anode for carbon electrodes
and 24000 C and 26000 0C respectively for metal electrodes. The temperature may reach 60000
0 to 70000 0C in the centre of the arc. Only from 60 to 70% of the heat is utilized an arc welding
to heat up and melt the metal. The remaining 30 to 40% is dissipated into the surroundings.
Welding Joint Design: Since welding joins metals, design for welding is chiefly concerned
with joints i.e. when to use a joint, how to weld it, where to place it, what to do and what not
5
to do. Selection and preparation of weld joint is an important step in the fabrication of a weld-
ment. Selection of correct joint design is very essential if welded members are to perform within
the load service, corrosive atmosphere and safety requirements. Not only must the product have
sufficient strength to perform well under the load conditions expected but it must be pleasing
in appearance also. Proper joint design is a vital part of a welding procedure because it helps to:
The weld joint design should be such that the welds can be tested non-destructively for nec-
essary quality control, especially if the welds are in pressurized or contaminates and inaccessible
areas. The consideration in joint includes safety, service, quality and cost.
Types of Welding Joints: While designing for welding it appears both logical nad fundamen-
tal to first consider the various forms of weld joints. A joint indicates the position where two or
more members of a structure meet and are to be joined by welding. Classification:
1. Butt Joint
2. Edge Joint
3. Tee Joint
4. Corner Joint
5. Lap Joint
6
Joint Design
Selection of Welding Joint

The selection of a suitable joint for a particular type of weldment depends upon the following
factors:
1. Base plate thickness
2. Geometry of structure
3. Magnitude of loading
4. Type of loading, i.e. tension, shear, impact, bending etc..
7
5. Cost of joint preparation
6. Number of passes
7. Electrode consumption
8. Chances and magnitude of distortion
9. Ease of welding
2.5 Procedure
1. 1. The edge of the given material is prepared to the required V-shape using grinding
machine.
2. The machine is set to the required current (75 amps).
3. Place the two work pieces on the table with required position as shown in figure.
4. The work pieces are kept in the required position and tack welding is performed on the
work pieces.
5. First run of welding is done to fill the gap and penetration of the weld ment by holding
the electrode at about 700 and moving the electrode to another end uniformly.
6. Second run of welding is done with proper weaving and uniform movement.
7. The scale formed is chipped with chipping hammer.
8. Filing is done to remove any spatter around the weld
2.6 Precautions
1. Never look at the arc with the naked eye. Always use a shield while welding.
2. Always wear the safety hand gloves, apron and leather shoes.
3. Ensure proper insulation of the cables and check for openings.
8
4. Care is taken to avoid arc blow, which will cause serious defect in the weldment.
5. Inflammable and combustible materials are removed from the vicinity of welding opera-
tions.
2.7 Pre Lab Viva Questions

1. Define permeability of molding sand?
2. Define cope, drag and cheek?
3. Define refractoriness of the sand material?
4. Define flow ability or the sand material?
5. Define dry strength or the sand mould?
2.8 Post Lab Viva Questions

1. What is a pattern? Explain different materials suitable for pattern making.
2. Name different types of patterns. Explain with neat sketch about split pattern and discuss
its use.
3. What are the requirements of a good gating system? Draw a sketch of a gating system
and explain the functions of various elements.
4. What are the essential properties of molding sand? Briefly explain them.
5. What is the function of a core? What are core prints?
9
LAB-2 ARC WELDING (LAP JOINT)
3.1 AIM
Prepare a LAP JOINT using Arc Welding Process

Wire Brush, Grinding Machine, Protective Equipment,
Welding Transformer, Electrodes, Tong, Chipping Hammer

Mild steel flat of 60 x45 x 10 mm3 – 2 No s.
3.4 THEORY
Definition: Electric arc welding is “a welding process where in coalescence is produced by
heating with an arc or arcs, with or without the application of pressure and with or without
the use of filler metals”. Electric arc welding is quite versatile and able to weld under many
conditions. High quality welds are produced. Metal is deposited rapidly and it is competitive
cost wise for many situations.
Electric arc welding is the most extensively used method of joining components of metallic
parts, the source of heat being an electric arc. An electric arc is a continuous stream of electrons
flowing trough some sort of medium between two conductors of an electric circuit and accom-
panied by intense heat generation and radiation.
Types of Welding Joints: While designing for welding it appears both logical nad fun-
damental to first consider the various forms of weld joints. A joint indicates the position where
two or more members of a structure meet and are to be joined by welding. Classification:
1. Butt Joint
2. Edge Joint
3. Tee Joint
4. Corner Joint
5. Lap Joint
10
Lap Joints
Single fillet and double fillet joints (shown in fig) are used on all thicknesses; double fillet
joint is better as compared to single fillet when the joint is subjected to severe loading. Single
fillet joints are not recommended on plates under bending, fatigue or impact loading conditions.
Plug weld (shown in fig) may be made without or with a hole in the upper member. This
joint is used where bottom or second plate is not easily accessible for fillet welding. Plug weld
11
can be employed to impart added strength to the structure.
3.5 Procedure
1. 1. The edge of the given material is prepared to the required V-shape using grinding
machine.
2. The machine is set to the required current (75 amps).
12
work pieces.
5. First run of welding is done to fill the gap and penetration of the weld ment by holding
the electrode at about 700 and moving the electrode to another end uniformly.
6. Second run of welding is done with proper weaving and uniform movement.
8. Filing is done to remove any spatter around the weld
3.6 Precautions
4. Care is taken to avoid arc blow, which will cause serious defect in the weldment.
tions.

1. Define permeability of molding sand?

1. What is a pattern? Explain different materials suitable for pattern making.
2. Name different types of patterns. Explain with neat sketch about split pattern and discuss
its use.
3. What are the requirements of a good gating system? Draw a sketch of a gating system
and explain the functions of various elements.
4. What are the essential properties of molding sand? Briefly explain them.
5. What is the function of a core? What are core prints?
13
LAB-3 SPOT WELDING (LAP JOINT)
4.1 AIM
To prepare a lap Joint on the given work pieces using spot welding equipment

Spot Welding Equipment, Snips and Gloves

GI Sheet of 50 x 50 mm — 2 Nos
4.4 THEORY
In resistance welding (RW) a low voltage (typically IV) and very high current (typically 15,000
A) is passed through the joint for a very short time (typically 0.25 s). This high amperage heats
the joint, due to the contact resistance of the joint and melts it. The pressure on the joint is
continuously maintained and the metal fuses together under this pressure. The heat generated
in resistance welding can be expressed as
H = k l2 R t
Where H = the total heat generated in the work, J
l = electric current, A
t = time for which the electric current is passing through the joint, s r = the resistance of
the joint, ohms
and k = a constant to account for the heat losses from the welded joint
The resistance of the joint, R is a complex factor to know because it is composed of
1. The resistance of the electrodes,
2. The contact resistance between the electrode and the work piece,
3. The contact resistance between the two work piece plates,
4. The resistance of the work piece plates.
The amount of heat released is directly proportional to the resistance. It is likely to be released
at all of the above-mentioned points, but the only place where a large amount of heat is to
be generated to have an effective fusion is at the interface between the two work piece plates.
Therefore, the rest of the component resistances should be made as small as possible, since the
14
heat released at those places would not aid in the welding.
Because of the squaring in the above, equation, the current, i needs to be precisely con-
trolled for any proper joint. The main requirement of the process is the low voltage and high
current power supply. This is obtained by means of a step down transformer with a provision to
have different tappings on the primary side, as required for different materials. The secondary
windings are connected to the electrodes which are made of copper to reduce their electrical re-
sistance. The time of the electric supply needs to be closely controlled so that the heat released
is just enough to melt the joint and the subsequent fusion takes place due to the force (forge
welding) on the joint. The force required can be provided either mechanically, hydraulically or
pneumatically. To precisely control the time, sophisticated electronic timers are available.
The critical variable in a resistance welding process is the contact resistance between the two
work piece plates and their resistances themselves. The contact resistance is affected by the sur-
face finish on the plates, since the rougher surfaces have higher contact resistance. The contact
resistance also will be affected by the cleanliness of the surface. Oxides or other contaminants
if present should be removed before attempting resistance welding.
15
4.5 Procedure
1. The two pieces to be joined by spot welding are placed between the two electrodes in the
required position.
2. Set the timer for which the current flows through the electrodes with reference to the
thickness of the plates
3. Press the foot lever, so that the movable electrode moves towards the fixed electrode.
4. This causes to develop a pressure of about 200-1000 Kg / cm2 on the sheets.
5. A low voltage and very high current is passed through the joint for a very short time. The
duration of the current flow is for about 2 sec (This high amperage heats the joint, due to
contact resistance at the joint and melts it).
6. Then the metal under electrodes pressure is squeezed and welded
7. Pressure is then released and the process is repeated until the job is completed.
8. The welding is carried out in a regular pattern as shown in fig.
4.6 Precautions
1. Proper pressure should be applied on the electrodes.
2. Correct electrode diameter needs to be chosen depending on the material thickness to be

joined.
3. Proper weld time should be selected for welding.
16
1. What are the process variables in explosive welding?
2. What are the modes of metal transfer in arc welding?
3. How is brazing different from welding and soldering?
4. Define solid state welding?
5. What are the functions of coating in coated electrode?
6. List out various defects caused in welding.

1. List out the sources of energy used for welding?
2. What is the use of filler material in welding?
3. Define carburizing flame and give its ratio?
4. Define oxidizing flame and give its ratio?
5. Define neutral flame and give its ratio?
6. Differentiate between TIG welding and MIG welding.
17
LAB-4 TUNGSTEN INERT GAS (TIG) WELDING
5.1 AIM
To prepare a V – Butt Joint Using TIG Welding.

Transformer, Rectifier and Argon gas cylinder

MS flat 50 x 60 X 10 mm3 —2 No.s Tong, Chipping Hammer, goggles Tungsten Electrode,
Ceramic Nozzle and Filler rod.
5.4 THEORY
The Endeavour of welder is always to obtain a joint which is as strong as the base metal and
at the same time, the joint is as homogeneous as possible. To this end, the complete exclusion
of oxygen and other gases which interfere with the weld pool to the detriment of weld quality
is very essential. In manual metal arc welding, the use of stick electrodes does this job to some
extent but not fully. In inert gas shielded arc welding processes, a high pressure inert gas flowing
around the electrode while welding would physically displace all the atmospheric gases around
the weld metal to fully protect it.
The shielding gases most commonly used are argon, helium, carbon dioxide and mixtures
of them. Argon and helium are completely inert and therefore they provide completely inert
atmosphere around the puddle, when used at sufficient pressure. Any contaminations in these
gases would decrease the weld quality.
Argon is normally preferred over helium because of a number of specific advantages. It re-
quires a lower arc voltage, allows for easier arc starting and provides a smooth arc action. A
longer arc can be maintained with argon, since arc voltage does not vary appreciably with arc
length.
It is more economical in operation. Argon is particularly useful for welding thin sheets and for
out of position welding.
The main advantage of Helium is that it can with stand the higher arc voltages. As a result
it is used in the welding where higher heat input is required, such as for thick sheets or for
higher thermal conductivity materials such as copper or aluminium. Carbon dioxide is the most
economical of all the shielding gases. Both argon and helium can be used with AC as well as DC
welding power sources. However, carbon dioxide is normally used with only DC with electrode
18
positive.
TUNGSTEN INERT GAS(TIG) WELDING Tungsten inert gas (TIG) welding is as inert
gas shielded arc welding process using non consumable electrode. The electrode may also contain
1 to 2% thoria mixed along with core tungsten or tungsten with 0.15 to 0.4% zirconia. The
pure tungsten electrodes are less expensive but will carry less current. The thoriated tungsten
electrodes carry high currents and are more desirable because they can strike and maintain stable
arc with relative ease. The zirconia added tungsten electrodes are better than pure tungsten
but inferior to thoriated tungsten electrodes. A typical TIG welding setup is shown in fig.
It consists of a welding torch at the centre of which is the tungsten electrode. The inert gas is
supplied to the welding zone through the annular path surrounding the tungsten electrode to
effectively displace the atmosphere around the weld puddle. The TIG welding process can be
used for the joining of a number of materials though the most common ones are aluminium,
magnesium and stainless steel.
The power sources used are always the constant current type. Both DC and AC power
supplies can be used for TIG welding. When DC is used, the electrode can be negative (DCEN)
or positive (DCEP). With DCEP is normally used for welding thin metals where as fro deeper
penetration welds DCEN is used. An Ac arc welding is likely to give rise to a higher penetration
than that of DCEP.
19
5.5 Procedure
1. Prepare the edges of the work pieces to be joined to the required V shape.
2. Finish the edges using emery paper.
3. Place the work pieces on the work table in the required position.
4. Set the current of the machine to 100 A.
5. Fix the tungsten electrode to the electrode holder.
6. Required size of the nozzle is selected and it is fixed to the torch
7. Adjust the inert gas flow rate to the required rate.
8. Select the filler rod (same as base metals) of required diameter.
9. Touch the electrode to the work, so that current flow will be established and then separated
by a small distance and the arc will be generated.
10. First tack weld is done on the work pieces.
11. Move the electrode slowly along the length of the joint with the filler rod, so that the filler
metal will be deposited in the joint.
12. Repeat the operation for the second pass, so that required amount of filler metal will be
deposited on the work pieces.
5.6 Precautions
20
4. Select the parameters of the machine properly based on the metals to be welded.
5. Set these parameters properly before performing the operation.
tions.

1. What is the use of flux in welding?
2. Write a short note on butt welding.
3. List out minimum six types of welding process.
4. Write a short note on the symbol of weld?

3. Write the constituents of electrode coating with their functions.
4. What is heat shrinkage in spot welding?
5. What is the effect of clearance in brazing?
21
LAB-5 PATTERN DESIGN AND MAKING
6.1 AIM
To Design and Manufacture a Wooden Pattern for a given Casting.

Wood Turning Lathe, Vernier Calipers, Spanner, chuck spanner, and Single Point Cutting tool,
Emery Paper

Teak wood of 50 x 50 x 130 mm3
6.4 THEORY
1. A pattern is a mold forming tool in the hands of foundry men.
2. Except for the various allowances a pattern exactly resembles the casting to be made.
3. A pattern may be defined as a model or form around which sand is packed to give rise to a
cavity known as mould cavity in which when molten metal is poured, the result is CAST
OBJECT.
Functions of a Pattern:
1. A pattern prepares a mold cavity for the purpose of making a casting.
2. A pattern may contain projections known as core prints if the casting requires a core and
need to be hallow.
3. Runner, gates and risers (used for introducing and feeding molten metal to the mold cavity)
may form the part of the pattern.
4. A pattern may help in establishing locating points on the mold and therefore on the casting
with a purpose to check the casting dimensions.
5. Pattern establishes the parting line and parting surfaces in the mold.
6. Patterns properly made and having finished and smooth surfaces reduce casting defects.
7. Properly constructed patterns minimize overall cost of the castings.
22
Pattern Materials:
The following factors assist in selecting proper pattern material:
The number of castings to be produced. Metal patterns are preferred when the production
quantity is large.
1. The dimensional accuracy and surface finish required for the castings.
2. Nature of molding process i.e., sand casting, permanent mold casting, shell molding, in-
vestment casting etc. Sand castings can be produced with the help of wooden patterns
whereas investment castings needs wax patterns.
3. Method of molding i.e., hand or machine molding.
4. Shape, complexity and size of the pattern.
5. Casting design parameters (i.e., minimum section thickness) and the complexity of the
cast part.
6. Type of the molding materials i.e., sand etc.
7. The chances of repeat orders.
Materials for making patterns Patterns may be constructed of the following materials. The
different materials have their own advantages, limitations and the field of applications.
1. Wood
2. Metal
3. Plastic
4. plaster and
5. Wax.
Allowances: A pattern is always larger in size when compared to normal casting, because
it carries certain allowances due to mechanical reasons and metallurgical reasons for example,
shrinkage allowance is the result of metallurgical phenomenon whereas machining, draft, distor-
tion, shake and other allowances are provided on the patterns because of mechanical reasons.
The various pattern allowances are:
1. Shrinkage or contraction allowance.
2. Machining or finishing allowance.
3. Draft or topper allowance.
4. Distortion or camber allowance.
5. Shake or rapping allowance.
Shrinkage Allowance: All most all cast metals shrink or contract volumetrically after
solidification and therefore the pattern to be obtain a particular sized casting is made oversize
by an amount equal to that of shrinkage or contraction. Different metals shrink at different rates
because shrinkage is the property of the cast metal or alloy. The metal shrinkage depends upon
the cast metal or alloy, pouring temperature of the metal or alloy, casting dimensions (size), and
Molding conditions (i.e., mold materials and molding methods employed).
Machine Allowance:
23
1. A castings is given an allowance for machining, because Castings get oxidized in the mold
and during heat treatment; scales etc., thus formed need to be removed.
2. It is intended to remove surface roughness and other imperfections from the castings. It
is required to achieve exact casting dimensions.
3. Surface finish is required on the casting.
The above factors necessitate the provision of extra metal on the castings or the Machin-
ing/allowance. How much extra metal or how much machining allowance should be provided,
depends upon the factors listed below:
1. Nature of metal i.e., ferrous or non ferrous. Ferrous metals get scared while nonferrous
metals do not.
2. Size and shape of the casting. Long castings tend to warp and need more material (i.e.,
allowance) to be added to ensure that after machining the casting will be alright.
3. The type of machining operation (i.e., grinding, milling, turning, boring etc).
4. Casting conditions i.e., whether casting conditions result in a rough casting or a semi
finished one.
5. Molding process employed. Die casting produces parts which need little machining al-
lowance whereas parts sand cast, require more machining allowance.
6. Number of cuts to be taken. Machining allowance is directly proportional to the number

of cuts required for finishing the casting.
7. The degree of surface finish desired on the cast part.
Problem: Design a Pattern for the casting shown in fig. which is to be made of steel by
considering shrinkage and machining allowance.
Solution: For Steel Shrinkage Allowance is 21mm/m.
For dimension 40, allowance is 40 x 21/1000 = 0.84 1.0 For dimension 30, allowance is 30
x 21/1000 = 0.63
For dimension 20, allowance is 20 x 21/1000 = 0.42
The pattern drawing with required dimensions taking shrinkage into account is shown in fig
24
Machining Allowance: Assume 2mm allowance on larger diameter size, 1.4mm on 30mm
diameter size and 1.6mm on smaller diameter size.
The pattern drawing with required dimensions taking shrinkage into account is shown in fig.
PATTERN MAKING
6.5 Procedure
1. The work piece is fixed between live centre and dead center of wood working lathe.
2. Adjust the machine to run the job to a required cutting speed.
3. Fix the cutting tool in the tool post and make sure that the axis of the job coincides with
the tip of the cutting tool.
4. Give the depth of cut and feed to the cutting tool.
5. Plain turning operation is performed until the diameter of the work piece reduces to 43
mm.
6. Step turning operation is performed according to the given dimensions.
7. Perform shoulder turning operation according to the dimensions shown in fig.
8. Frequently check the dimensions by using vernier calipers.
9. Finish the work piece using emery paper
25
6.6 Precautions
1. The work piece should be held rigidly between the two centers before operating the ma-
chine.
2. Tool should be properly ground, fixed at correct height and properly secured, and work
also be firmly secured.
3. Optimum machining conditions should be maintained.

5. Define collapsibility of the sand mould?
6. . Define hot strength of the sand material?

1. Define Adhesiveness of the sand material?
2. What is the effect of cohesiveness of the sand material?
3. What is the use of cone?
4. What is the use of chaplets?
5. What is the use of facing sand?
6. Define parting line in casting.
26
LAB-6 PATTERN DESIGN AND MAKING
7.1 AIM
To Design and Manufacture a Wooden Pattern for a given Casting.

Wood Turning Lathe, Vernier Calipers, Spanner, chuck spanner, and Single Point Cutting tool,
Emery Paper

Teak wood of 50 x 50 x 130 mm3
7.4 THEORY
1. A pattern is a mold forming tool in the hands of foundry men.
2. Except for the various allowances a pattern exactly resembles the casting to be made.
3. A pattern may be defined as a model or form around which sand is packed to give rise to a
cavity known as mould cavity in which when molten metal is poured, the result is CAST
OBJECT.
Functions of a Pattern:
1. A pattern prepares a mold cavity for the purpose of making a casting.
2. A pattern may contain projections known as core prints if the casting requires a core and
need to be hallow.
3. Runner, gates and risers (used for introducing and feeding molten metal to the mold cavity)
may form the part of the pattern.
4. A pattern may help in establishing locating points on the mold and therefore on the casting
with a purpose to check the casting dimensions.
5. Pattern establishes the parting line and parting surfaces in the mold.
6. Patterns properly made and having finished and smooth surfaces reduce casting defects.
7. Properly constructed patterns minimize overall cost of the castings.

Pattern Making Machines:
Besides the hand tools, a modern pattern makers shop needs some power-driven machines
also. These machines help the pattern maker in
27
1. Increasing production.
2. Improving accuracy and maintaining consistency in the patterns.
3. Performing many more operations easily and conveniently.
The following tools are used for different purposes by a pattern maker.
1. Measuring, Making and Layout Tools
Steel rule
Shrinkage rule
Caliper
Divider
Marking gauge
Trammels
Try square
T-bevel
Combination square.
2. Tools for clamping purposes:
Hand vice
Pattern makers vice
Bar clamp
C-clamp
Hand screw
Pinch dog ( to hold wooden pieces together for joining etc.).
3. Sawing Tools:
Coping saw
Bow saw
Compass saw
Rip saw
Crosscut saw
panel saw
Back saw
Dovetail saw
Miter saw with miter box.
Wood Working Lathe: The woodworking lathe is one of the most important machines used
in a carpentry shop. This is employed primarily for turning jobs in making cylindrical parts.
However, by suitably manipulating the tools, tapers, radii, and other irregular shapes can also
be easily turned.
It resembles the engine lathe most frequently used in the machine shop and consists of a cast
iron bed, a head stock, tail stock, tool rest, live and dead centers, and a speed control device
(shown in Fig). The drive, in modern lathes, is individual motor driven; and a cone pulley on
the head stock spindle is connected by a belt to a cone pulley on the motor shaft.
28
In practice, the work piece is either clamped between two centers or on a face plate. Long jobs
are held between the centers and turned with the help of gouge, skew chisel, parting tool, etc.
Generally, the lathe is supplied together with a number of accessories for making it useful for a
variety of jobs. The size of a woodworking lathe, as in the engine lathe, is usually specified in
terms of the so-called swing of the lathe and the maximum distance between centers.
Allowances A pattern is always larger in size when compared to normal casting, because it
carries certain allowances due to mechanical reasons and metallurgical reasons for example,
shrinkage allowance is the result of metallurgical phenomenon whereas machining, draft, and
other allowances are provided on the patterns because of mechanical reasons. The various
pattern allowances are:
1. Shrinkage or contraction allowance.
2. Machining or finishing allowance.
3. Draft or topper allowance.
4. Distortion or camber allowance.
5. Shake or rapping allowance.
Draft or Taper Allowance It is given to all surfaces perpendicular to the parting line. Draft
allowance is given so that pattern can be easily removed from molding material which is tightly
packed around it with out damaging the mold cavity. The amount of Taper depends upon
1. Shape and size (length) of the pattern in the depth direction in contact with the mold
cavity.
2. Molding methods.
3. Mold materials.
29
Draft allowance is imparted on internal as well as external surfaces; of course it is more on
internal surfaces Taper on external surfaces = 10 to 25 mm/meter or 10 - 20 .
Taper on internal surfaces = 40 to 65 mm/meter or 30 – 40 .
Problem: Design a Pattern for the casting shown in fig. which is to be made of steel by
considering Shrinkage and Draft allowance.
Solution:
For Steel Shrinkage Allowance is 21mm/m.
For dimension 60, allowance is 60 x 21/1000 = 1.26 1.3 For dimension 20, allowance is 20
x 21/1000 = 0.42 The pattern drawing with required dimensions taking shrinkage into account
is shown in fig.
Draft Allowance: Assume 20 taper for external details and 40 for internal details. For the
above casting taper required is External = 61.3 x tan 20 = 2.14 mm. Internal = 61.3 x tan 40
= 4.3 mm.
After providing this taper the pattern drawing is as shown in fig. The procedure for preparing
the pattern is given below.
30
7.5 Procedure
1. The given work piece is prepared using the Jack plane.
2. The work piece is cut by using sawing tools according to the dimensions shown in fig 2
and 3.
3. Finish the same using wood rasp file
4. Fix the work piece on wood working lathe.
5. Fix a drill of required diameter in the tail stock.
6. Perform drilling operation according to the dimensions shown in fig 2.
7. Fix a boring tool in tool post.
8. Swivel the compound rest to the required angle and perform boring operation according
to the dimensions shown in fig3.
9. Finish the work using emery paper.
7.6 Precautions
1. The work piece should be held rigidly in the vice while performing cutting operation.
2. The work piece should be held rigidly in the chuck of lathe.
3. Make sure that the axis of drill coincides with the axis of work.
4. Optimum machining conditions should be maintained.
31
6. Define hot strength of the sand material?

32
LAB-7 SAND PROPERTIES TESTING
8.1 AIM
To Determine the Grain size, Permeability and Compressive Strength of the Moulding Sand.
8.2 TOOLS REQUIRED

Sieves of different numbers and cubical block

Sieve Shaker, Permeability Apparatus and
Compression Strength Testing Machine.

Moulding Sand.
8.5 THEORY
PROPERTIES OF MOULDING SAND Moulding sand must possess some properties like
permeability, flowability collapsibility, adhesiveness, cohesiveness or strength and refractoriness.
The properties are determined not only by the chemical composition, but by the amount of
clayey matter in the sand, by its moisture content, and lastly by the shape and size of the silica
sand grains.
Porosity: Molten metal always contains a certain amount of dissolved gases, which are
evolved when the metal freezes. Also, the molten metal ,coming in contact with the moist sand,
generates steam or water vapour .If these gases and water vapour evolved by the moulding sand
do not find opportunity to escape completely through the mould they will form gas holes and
pores in the casting. The sand must, therefore, be sufficiently porous to allow the gases or
moisture present or generated with in the moulds to be removed freely. When the moulds are
poured. This property of sand is called porosity or permeability.
Flowability: Flowability of moulding sand refers to its ability to behave like a fluid so that,
when rammed it will flow to all portions of a mould and pack all-round the pattern and take
up the required shape. The sand should respond to different moulding processes. Flowability
increases as clay and water content increases.
Collapsibility: After the molten metal in the mould gets solidified the sand mould must be
33
collapsible so that free contraction of the metal occurs, and this would naturally avoid the tear-
ing or cracking of the contracting metal.
Adhesiveness: The sand particles must be capable of adhering to another body, i.e.. they
should cling to the sides of the moulding boxes. It is due to this property that the sand mass
can be successfully held in a moulding box and it does not fall out of the box when it is removed.
Cohesiveness or Strength: This is the ability of sand particles to stick together. Insuffi-
cient strength may lead to a collapse in the mould or its partial destruction during conveying,
turning over or closing. The closing may also be damaged during pouring the molten metal.
The strength of moulding sand must, therefore, be sufficient to permit the mould to be formed
to the desired shape and to retain this shape even after the hot metal is poured in the mould.
This property of sand in its green or moist state is known as green strength. A mould having
adequate green strength will retain its shape and will not distort or collapse even after the pat-
tern is removed from moulding box. The strength of sand that has been dried or baked is called
dry strength .It must have then strength to withstand erosive forces due to molten metal, and
retain its shape.
Refractoriness:The sand must be capable of withstanding the high temperature of the

molten metal with out fusing. Moulding sands with poor refractoriness may burn on to the
casting. Refractoriness is measure by the sinter point of the sand rather than its melting point.
SAND TESTING Grain Size Grain size of sand is designated by a number called ”Grain
Fineness Number” that indicates the average size as well as proportions of smaller and larger
grains in the mixture.
1. The apparatus required for determining grain fineness consists of a number of standard
sieves mounted one above the other, on a power driven shaker. The shaker vibrates the
sieves and the sand placed on the top sieve gets screened and collects on different sieves
depending upon the various sizes of grains present in the moulding sand.
2. In this test place five standard sieves mounted one above the other on a stand and under
the bottom most sieve is placed a pan. The top sieve is the coarsest and bottom most
sieve is the finest of all the sieves.
3. A sample of dry sand is placed in the upper most sieve and place the sieve stand on the
vibrator.
4. Then vibrate the sieve stand for a definite period of time.
5. An amount of sand may be retained on each sieve and same is weighed.
6. Calculate the AFS grain fineness number
OBSERVATIONS AND CALCULATIONS:

PERMEABILITY TEST:
1. 2000 cc of water held in the inverted bell jar is allowed to pass through the sand specimen.
2. A situation comes when the liquid entering the specimen equals the air escaped through
the specimen.
3. This gives a stabilized pressure reading on the manometer and the same can be read on
the vertical scale.
34
4. Simultaneously, using as top watch the time required for 2000cc of water to pass through
the sand of specimen is also recorded.
Permeability number can be determined by the following relation;

Permeability Number= V .H / A.P.T.
Where V = volume of air passed through the specimen H = height of the specimen
A = area of the specimen
T = time taken by the air to pass through the sand specimen P = pressure recorded by
manometer. COMPRESSION STRENGTH TEST
1. The specimen is held between the grips.
2. Hand wheel when rotated actuates a mechanism which builds up hydraulic pressure on
the specimen.
3. Dial indicator fitted on the tester measures the deformation occurring in the specimen.
4. As the applied load is continues, the specimen breaks at a particular load.
5. At this point note down the reading of dial indicator which directly gives the compression
strength of the sand.
8.6 Precautions
1. For calculating grain size of sand, sand taken should be free from dirt particles.
2. For calculating the compression strength, load is applied gradually on the specimen.

1. 1. Define cope, drag and cheek?

35
LAB-8 CASTING FOR A SOLID PATTERN
9.1 AIM
To Prepare a Casting for the given Solid Pattern using Green Sand Moulding Processes

Pattern, Shovel, Riddle, Rammer, Trowel, Slick, Lifter, Strike – Off bar, Draw – spike, Mallet,
Moulding Boxes, Vent rod, Runner, Riser, and Swab

Moulding Sand.
9.4 THEORY
MOULDING SAND The principal material used in the foundry shop for moulding is the
sand. This is because it possesses the properties vital for foundry purposes.
Sources: All sands are formed by the breaking up of rocks due to the action of natural
sources such as frost, wind, rain, heat and water currents. Rocks however are very complex in
their composition and sands contain most of the elements of the rocks of which they fragment.
For this reason, sands in different parts of the world vary considerably. Today, sand is obtained
from places which probably once were bottoms and banks of rivers and sand dunes.
PRINCIPAL INGREDIENTS: The principal ingredients of moulding of sands are:
1. Silica sand grains
2. clay
3. moisture and
4. miscellaneous materials
Silica in the form of granular quartz, itself sand is the chief constituent of moulding sand.
Silica sand contains from 80 to 90 percent silicon dioxide and is characterized by a high soften-
ing temperature and decomposition of granite, which is composed of feldspar and quartz. The
feldspar, when decomposed, becomes clay (hydrous aluminium silicate). However, silica sand
grains impart refractoriness, chemical resistivity, and permeability to the sand. They are speci-
fied according to their average size and shape.
Clay is defined as those particles of sand (under 20 microns in diameter) that fail to settle
at a rate of 25mm per minute, when suspended in water. Clay consists of two ingredients: fine
36
silt and true clay. Fine silt is a sort of foreign matter or mineral deposit and has no bonding
power. It is the true clay which imparts the necessary bonding strength to the mould sand, so
that the mould does not lose its shape after ramming. True clay is found to be made up of
extremely minute aggregates of crystalline, usually flake-shaped, particles called clay minerals.
Most moulding sands for different grades of work contain 5-20 percent clay.
Moisture, in requisite amount furnishes the bonding action of clay; it penetrates the mix-
ture and forms a microfilm which coats the surface of flake-shaped clay particles. The bonding
quality of clay depends on the maximum thickness of water film it can maintain .The bonding
action is considered best if the water added is the exact quantity to form the film. On the other
hand the bonding action is reduced and the mould gets weakened if the water is in excess .The
water should be between 2-8percent.
Miscellaneous materials that are found in addition to silica and clay, in mouding sand are
oxide of iron, limestone, magnesia, soda, and potash .The impurities should be below 2 percent.
Gating system:
Gating system refers to all those elements which are connected with the flow of molten metal
from the ladle to the mould cavity. The various elements that are connected with a gating system
are:
1. Pouring basin
2. Sprue
3. Sprue base well
4. Runner
5. Runner extension
6. Ingate
7. Riser
Gates:
Also called the ingates, these are the openings through which the molten metal enters the
mould cavity. Depending on the application, various types of gates are used in the casting
design. They are:
1. Top Gate
2. Bottom Gate
3. Parting Gate
Top Gate:
37
This is the type of gating through which the molten metal enters the mould cavity from the top
as shown in fig. since the first metal entering the gate reaches the bottom and hotter metal is
at the top, a favourable temperature gradient towards the gate is achieved. Also the mould is
filled very quickly. But as the metal falls directly into the mould cavity through a height, it is
likely to cause mould erosion. Also because it causes turbulence in the mould cavity it is porne
to form dross and as such top gate is not advisable for those materials which are likely to form
excessive dross. It is not suggested for non ferrous alloys and is suggested only for ferrous alloys.
It is suitable only for simple casting shapes which are essentially shallow in nature.
Bottom Gate
When molten metal enters the mould cavity slowly as shown in fig., it would not cause any
mould erosion. Bottom gate is generally used for very deep moulds. It takes higher time for
filling the mould and also generates a very unfavourable temperature gradient.
9.5 PROCEDURE
MAKING A GREEN SAND MOULD
38
1. First the pattern is placed with its larger diameter side is on a mould board.
2. The drag section of the flask is set over the pattern on same board.
3. After powdering the pattern with lycopodium, talc or graphite, a 15 to 20 mm layer of

facing sand is riddled over the pattern.
4. The drag is then filled by layers of green sand mixture from 70 to 100 mm thick, compacting
each layer with rammer.
5. The top of the mould is rammed with the butt end of a rammer. The object of ramming the
sand is to consolidate it, there by preventing the cavity of the mould from being enlarged
by the metal.
6. After the sand is rammed a strickle is used to scrape off the excess sand level with the top
of the flask.
7. The mould is then vented by sticking it with a fine stiff wire at numerous places (The vent
holes should not reach the pattern by 15 to 20 mm as otherwise they may spoil the mould.
Moreover, the metal may run in to the vent holes during pouring. These vent holes permit
the escape of gases generated in the mould when the molten metal comes in contact with
moist sand).
8. A small amount of loose sand is sprinkled over the mould and bottom board is placed on
the top. The drag is rolled over, the moulding board is removed, and the upper surface is
39
sprinkled with parting sand (The parting sand is used to prevent the joints between the
halves of a mould from adhering to one another when the two parts of the moulding box
are separated).
9. The cope section of the flask is then assembled.
10. Tapered wooden pegs to serve as sprue and riser are placed in proper position as shown
in figure on the pattern which is riddled over with facing sand and then cope is filled with
green sand.
11. The operation of filling, ramming and venting of the cope proceed in the same manner as
in the drag.
12. A funnel shaped opening is scooped out at the top of the sprue to from the pouring basin.
13. Next the cope is lifted off and placed on a board with the parting line upward.
14. An iron bar is now pushed down to the pattern and rapped sideways .So as to loosen the
pattern and prevents any sand from sticking to the pattern.
15. Next pattern is drawn out using draw spike.
16. Runners are cut in the cope according to the dimensions shown in fig.
17. Cut the gates in the drag according to the dimensions shown ( Use Top Gating System).
18. If needed all the cavity edges are repaired.
19. Finally the mould is assembled, the cope being carefully placed on the drag so that the
flask pins fit into the bushes.
20. The mould is then ready for pouring.
21. Molten metal (Aluminium) is prepared in the high frequency electrical induction furnace.
22. Take the molten metal from crucible in to the ladle.
23. Pour the molten metal from the ladle into the pouring basin so that the molten metal will
enter into the mould cavity through the sprue, runner and gate.
24. Allow the molten metal to solidify.
25. Then break the mould to obtain desired casting.
9.6 Precautions
1. Care must be taken to have proper alignment of the pattern as well as moulding boxes.
2. Sand should be rammed properly and evenly.
3. The pattern should be rapped gently and with drawn carefully with out damaging the
mould cavity.
4. Care should be taken to avoid over cuts and corners.
5. Care should be taken while pouring the molten metal in to the cavity.
40

41
LAB-9 CASTING FOR A SPLIT PATTERN
10.1 AIM
To Prepare a Alluminium Casting for the given Split Pattern using Green Sand Moulding Pro-
cesses.

Pattern, Shovel, Riddle, Rammer, Trowel, Slick, Lifter, Strike – Off bar, Draw – spike, Mallet,
Moulding Boxes, Vent rod, Runner, Riser, and Swab

Moulding Sand.
10.4 THEORY
MOULDING SAND The principal material used in the foundry shop for moulding is the
sand. This is because it possesses the properties vital for foundry purposes.
TYPES OF MOULDING SANDS:
GREEN SAND: It is a mixture of silica sand with 18 to 30 percent clay, having a total
water of from 6 to 8 percent. The clay and water furnish the bond for green sand. It is fine, soft,
light, and porous. Being damp, when squeezed in the hand, it retains the shape, the impression
given to it under pressure. Moulds prepared in this sand are known as greensand moulds.
DRY SAND: Green sand that has been dried or baked after the mould is made is called
dry sand. They are suitable for larger castings. Moulds prepared in the sand are known as dry
sand moulds.
LOAM SA: Loam sand is high in clay as much as 50 percent or so and dries hard. This is
particularly employed for loam moulding usually for large castings
FACING SAND: Facing sand forms the face of the mould. It is used directly next to
the surface of the pattern and it comes into contact with the molten metal when the mould is
poured. Consequently, it is subjected to the severest conditions and must possess high strength
and refractoriness. It is made up silica sand and clay, with out the addition of used sand.
Different forms of carbon are used to prevent the metal from burning into the sand. They are
some times mixed with 6 to15 times as much fine moulding sand to make facings. The other
types of sands are Backing Sand, System Sand, Parting Sand, and Core Sand.
SAND ADDITIVES:
Additives are the materials generally added to the sand mixture to develop special properties
in the mould and consequently in castings.
MISCELLANEOUS MOULDING MATERIALS: These are the moulding materials
that are used in foundry procedures. They include fire clay, clay wash, parting materials and
42
core binders.
Gating system: Gating system refers to all those elements which are connected with the
flow of molten metal from the ladle to the mould cavity. The various elements that are
connected with a gating system are:
1. Pouring basin
2. Sprue
3. Sprue base well
4. Runner
5. Runner extension
6. Ingate
7. Riser
Gates:
Also called the ingates, these are the openings through which the molten metal enters the
mould cavity. Depending on the application, various types of gates are used in the casting
design. They are:
1. Top Gate
2. Bottom Gate
3. Parting Gate
Parting Gate:
This is the most widely used gate in sand castings. As the name implies, the metal enters
the mould at the parting plane when part of the casting in the cope and a part in the drag as
shown in fig. For the mould cavity in the drag, it is a top gate and for the mould cavity in the
cope it is a bottom gate. Thus this type of gating tries to derive the best of both the types of
gates. Of all the gates this is also the easiest and most economical in preparation. However, if
the drag portion of the mould cavity is deep, it is likely to cause mould erosion and aggravate
dross formation and air entrapment in the case of non ferrous alloys. This can be somewhat
reduced by making the gate area large such that the liquid metal velocity is minimized and it
flows slowly along the walls into the mould cavity.
43
Melting Furnaces and Practice: A furnace is used to melt the metal. Different furnaces
are employed for melting ferrous and non ferrous materials. A furnace contain high temperature
zone surrounded by a refractory wall structure which with stands high temperatures and being
insulating minimizes heat losses to the surroundings.
Furnaces for Melting:

1. Gray Cast Iron
Cupola
Air Furnace
Rotary Furnace
Electric Arc Furnace
2. Steel
Open Hearth Furnace
Electric Furnace
Converter
3. Non - Ferrous Metals
Crucible Furnaces
Pot Furnaces
Reverberatory Furnaces
Rotary Furnaces
Induction Furnaces
Electric Arc Furnaces.
Induction Furnace for Melting Aluminium: Induction furnace consists of a refractory

crucible placed centrally inside water cooled copper coil and packed into position by ramming
refractory bricks tightly between the crucible and copper coil which is precovered with wet re-
fractory dried into a hard mass. Induction furnaces can be of two types:
1) Tilting Type
2) Scooping type.
44
Operation: Metal charge is placed in the crucible of furnace. A current is passed through
the copper coils which act as the primary of a transformer and the metal charge becomes the
secondary. Heavy alternating secondary currents thus induced in the metal charge by elec-
tromagnetic induction create heat because the metal charge offers resistance to the passage of
secondary currents. This heat developed in the skin of metal charge reaches inside by conduction
and melts the charge. After the melting has completed it is taken into ladles using a scoop.
10.5 PROCEDURE
MAKING A GREEN SAND MOULD
1. To make the green-sand mould the sand must be properly tempered before it can be used.
If the sand is too dry, additional water is added or if too wet, dry sand is added until it
has the proper temper. To check the sand for proper temper, a handful is grasped in the
first. The pressure is released, and sand is broken in two sections. The sections of sand
should retain their shape and the edges of the break should be sharp and firm.
2. The surface of the mould which comes in contact with molted metal forms the most
important part in green-sand moulds. In order to give the casting a clean and bright
surface and to prevent the sand from burning on the face of the mould a layer of facing
sand is given surrounding the pattern.
3. It is common practice to coat the surfaces of sand mould with refractory materiel to
produce a smooth skin on the castings. The material ordinarily used for this purpose is
graphite, coke, charcoal, gas carbon, etc.
4. First one-half of the pattern is placed with its flat surface on a mould board, and the drag
section of the flask is set over the pattern on same board.
5. A 15 to 20 mm layer of facing sand is riddled over the pattern.
6. The drag is then filled by layers of green sand mixture from 70 to 100 mm thick, compacting
each layer with rammer. The top of the mould is rammed with the butt end of a rammer.
The object of ramming the sand is to consolidate it, there by preventing the cavity of the
mould from being enlarged by the metal.
45
7. After the sand is rammed strike off bar is used to scrape off the excess sand level with the
top of the flask.
8. The mould is then vented by sticking it with a fine stiff wire at numerous places. The vent
holes should not reach the pattern by 15 to 20 mm as otherwise they may spoil the mould.
Moreover, the metal may run in to the vent holes during pouring. These vent holes permit
the escape of gases generated in the mould when the molten metal comes in contact with
moist sand.
9. The drag is rolled over and the upper surface is sprinkled with parting sand. The parting
sand is used to prevent the joints between the halves of a mould from adhering to one
another when the two parts of the moulding box are separated.
10. The remaining half of the pattern and the cope section of the flask are then assembled.
11. Place the Sprues and Risers at the required places shown in fig.
12. And then cope is filled with green sand.
13. The operation of filling, ramming and venting of the cope proceed in the same manner as
in the drag.
14. Following these operations the wooden pegs are withdrawn from the cope and a funnel
shaped opening is scooped out at the top of the sprue to form the basin.
15. Next the cope is lifted off and placed on a board with the parting line upward.
16. An iron bar is now pushed down to the pattern and rapped sideways .So as to loosen the
pattern and prevents any sand from sticking to the pattern.
17. Next the pattern is drawn out and the runners and gates are cut in the drag from the
pattern to the sprue as shown in fig.
18. Finally the mould is assembled, the cope being carefully placed on the drag so that the
flask pins fit into the bushes.
19. Before pouring the molten metal the cope is sufficiently loaded to prevent it from floating
up when the metal is poured. The completed mould is shown in fig.
20. Pour the molten metal from the ladle into the pouring basin so that the molten metal will
enter into the mould cavity through the sprue, runner and gate.
21. Allow the molten metal to solidify and break the mould to obtain desired casting.
10.6 Precautions
1. Care must be taken to have proper alignment of the pattern as well as boxes.
2. Sand should be rammed properly and evenly.
3. The pattern should be rapped gently and with drawn carefully with out damaging the
mould cavity.
4. Care should be taken to avoid over cuts and corners.
5. Care should be taken while pouring the molten metal in to the cavity.
46

47
LAB-10 STUDY OF PROGRESSIVE DIE
11.1 AIM
To study a progressive tool and perform blanking and piercing operations. To determine the
punching force and blanking force theoretically and compare the same with obtained readings.

Hydraulic Press

Progressive tool, Clamps and Blank.
11.4 SPECIFICATIONS
1. Capacity: 25 tons
2. Distance between columns: 865x300 mm2
3. Distance between ram to bed: minimum 180mm and maximum 915mm
4. Travel of ram: 180mm
5. Power of motor: 5 H.P.
11.5 THEORY
SHEET METAL WORKING OR PRESS WORKING OF SHEET METAL Press
working may be defined as a chip less manufacturing process by which various components are
made from sheet metal. This process is also termed as cold stamping. A frame which supports
a ram or a slide and a bed, a source of mechanism for operating the ram in line with and normal
to the bed. The ram is equipped with suitable punch and a die block is attached to the bed .A
stamping is produced by the down ward stroke of the ram when the punch moves towards and
into the die block. The punch and die block assembly is generally termed as a”die set” or simply
as a “die”. Press working operations are usually done at room temperature. In this process, the
wall thickness of the parts remains almost constant and differs only slightly from the thickness
of the initial sheet metal. The initial material in cold press working is: low carbon steels, ductile
alloy steels, copper and its alloys, aluminium and its alloys, as well as other ductile materials
from 10th of a mm to about 6 or 8 mm thick.
Elastic recovery or spring back. In metal working processes, the total deformation imparted to
a work piece will be the sum of elastic deformation and plastic deformation. We also know the
48
elastic deformation is recoverable where as plastic deformation is permanent. So, at the end of
a metal working operation, when the pressure of metal is released, there is an elastic recovery
by the material and the total deformation gets reduced a little. This phenomenon is called as
“Springback”.This phenomenon is of more importance in cold working operations, especially in
forming operations such as bending etc .Spring back depends upon the yield point strength of a
metal. The higher the yield point strength of a metal, the greater the spring back. The amount
of spring back for a forming operation is difficult to predict and cut- and try methods are most
satisfactory to account for it. To compensate for spring back, the cold deformation must always
be carried beyond the desired limit by an amount equal to the spring back.
Press operation: The sheet metal operations done on a press may be grouped into two
categories, cutting operations and forming operations.
In cutting operations, the work piece is stressed beyond its ultimate strength. The stresses
caused in the metal by the applied forces will be shearing stresses.
In forming operations, the stresses are below the ultimate strength of the metal. In this op-
eration, there is no cutting of the metal but only the contour of the work piece is changed to get
the desired product. The cutting operations include: blanking, punching, notching, perforating,
trimming, shaving, slitting and lancing etc.The forming operations include: bending, drawing,
redrawing and squeezing. The stresses induced in the metal during bending and drawing oper-
ations are tensile and compressive and during the squeezing operations these are compressive.
Blanking: Blanking is the operation of cutting a flat plate from sheet metal. The article
punched out is called the blank and is the required product of the operation. The hole and
metal left behind is discarded as waste. It is usually the first step of series of operations.
Punching: It is a cutting operation by which various shaped holes are made in sheet metal
.Punching is similar to blanking except that in punching , the hole is the desired product , the
material punched out to form the hole being waste.
Perforating: This is a process by which multiple holes which are very small and close
together are cut in flat work material .
Trimming: This operation consists of cutting unwanted excess material from the periphery
of a previously formed component.
Shaving: The edges of a blanked part are generally rough, uneven and un square. Accurate
dimensions of the part are obtained by removing a thin strip of metal along the edges.
Slitting: It refers to the operation of making incomplete holes in a work piece. Lancing:
49
This is a cutting operation in which a hole is partially cut and then one side is bent down to
form a sort of tab or louver. Since no metal is actually removed, there will be no scrap.
Bending: In this operation, the material in the form of flat sheet or strip is uniformly
strained around a linear axis which lies in the neutral plane and perpendicular to the lengthwise
direction of the sheet metal.
Drawing: This is a process of a forming a flat work piece into a hollow shape by means of
a punch which causes the blank to flow into a die cavity
TYPES OF DIES:
The dies may be classified according to the type of press operation and according to the
method of operation.
Types of press operation: According to this criterion, the dies may be classified as:
cutting dies and forming dies.
Cutting dies: The dies are used to cut the metal. They utilize the cutting or shearing
action. The common cutting dies are: blanking dies, piercing dies, perforating dies, notching,
trimming, shaving dies etc.
Forming dies: These dies change the appearance of the blank without removing any stock.
These dies include bending dies, drawing dies, squeezing dies etc.. Method of operation: Ac-
cording to this criterion, the dies may be classified as: single operation dies or simple dies,
compound dies, combination dies, transfer dies, progressive dies and multiple dies.
STUDY OF PROGRESSIVE DIE:
50
A progressive or follow on die has a series of stations. At each station an operation is
performed on the work piece during a stroke of the press. Between strokes the piece in the metal
strip is transferred to the next station. A finished work piece is made at each stroke of the press.
A progressive die is shown in fig. while the piercing punch blanks out a portion of the metal in
which two holes had been pierced at a previous station Thus after the stroke two holes will be
punched each stroke of the press produces a required finished component. Principle of metal
cutting:
The cutting of sheet metal in the press work is a shearing process. The punch is of the same
shape as of the die opening except that it is smaller on the each side by an amount known as
clearance. As the punch touches the material and travels downward, it pushes the material into
the die opening. The material is subjected to both tensile and compressive stresses as shown in
fig (a).
51
Stresses will be highest at the edges of punch and die and the material will start cracking
there. The various steps in the rupture or facture of material can be written as stressing the
material beyond the elastic limits; plastic deformation reduction in area fracturing starts in the
reduced area and becomes complete. If the clearance between punch and die is correct, the
cracks starting from the punch and die edges will meet and the rupture is complete as shown in
fig (b). If the clearance is too large or too small the cracks do not meet and ragged edge results
due to the material being dragged and torn through the die.
Clearance: The die opening must be sufficiently larger than the punch to permit a clean
fracture of the metal. This difference in dimensions between the mating members of a die set is
called clearance. This clearance is applied in the following manner:
c is the amount of clearance per side of the die opening.

1. When the hole has to be held to size, i.e. the hole in sheet metal is to be accurate, and
slug is to be discarded the punch is made to the size of hole and the die opening size is
obtained by adding clearance to the punch size shown in fig (a).
2. In blanking operation where the slug or blank is desired part and has to be held to size
the die opening size equals the blank size and the punch size is obtained by subtracting
the clearance from the die opening size shown in fig (b).
The clearance is a function of the kind, thickness and temper of the work material harder
materials requiring clearance than soft materials, the exception being aluminium. The usual
clearances per side of the die, for various materials, are given below in terms of the stock
thickness, t:
For brass & soft steel, c=5% of t For mild steel, c=6%of t For hard steel, c=7% of t For
Aluminium c=10% of t
The total clearance between punch and die size will be twice these figs these clearances are
for blanking and piercing operations.
The clearance may also be determined with the help of the following equation
c=0.0032t X τs Where τs is the shear strength of the material in N/mm2 .
52
Cutting forces: In cutting operation as the punch in its downward movement enters the
material it need not penetrate the thickness of the stock in order to affect complete rupture of
the part. The distance which the punch enters in to the work material to cause rupture to take
place is called “penetration” and is usually given as percentage of the stock thickness. The %
penetration depends on the material being cut and also on the stock thickness. When a hard and
strong material is being cut very little penetration of the punch is necessary to cause fracture.
With softer the penetration will be greater. The percentage penetration is also depends upon
the stock thickness, being smaller for thinner sheets.
The max force Fmax in newtons needed to cut a material is equal to :

For a circular blank of diameter D mm and of thickness t mm the maximum cutting force
will be given as: Fmax= π D t τ s = P t τ s .
Where P is the perimeter of the section to be blanked
For rectangular blanks the length L and width b it is
Fm ax= 2(L+b) t τs
11.6 PROCEDURE
1. Fix the punch to the ram of the press.
2. Fix the die on the bed of the machine using clamps, bolts and nuts.
3. Place the blank of required size between the die and punch.
53
4. Apply pressure hydraulically on the blank through the punch so that piercing will takes
place at the first station.
5. Note down the reading of the pressure gauge which directly gives the force required to
perform the piercing operation.
6. Move the blank in forward direction until it touches the stopper on the die.
7. Again apply pressure hydraulically on the blank so that piercing punch blanks out a
portion of the metal in which already two holes had been pierced. At the same time
piercing operation takes place at the first station.
perform the piercing and blanking operations.
9. Difference of the two readings gives the force required to perform blanking operation.
10. Compare the values with the theoretically obtained values.
11. The process may be repeated to produce the components in mass production.
OBSERVATIONS & CALCULATIONS: Piercing Force (Fp) =

Blanking & Piercing Force (Fbp) =
Blanking Force (Fb = Fp - Fbp) =
Maximum force needed to cut material is Fmax = P. t. τs . Where P is the Perimeter of the
blank
t is the thickness of the blank
τs . is the shear strength of the material.
11.7 Precautions
1. The die should be properly clamped to the bed of the machine and it is not disturbed
during the process.
2. The punch is properly fixed to the ram of the machine.
3. The load should be applied uniformly on the blank.
4. The ram should be fed slowly towards the die and make sure that it is properly in line
with the die.

1. Define forming in terms of bending?
2. What is meant by swaging?
3. List out the factors effecting shearing operation?
4. What type of metals is preferred for wire drawing?
5. What is meant by grain growth?
6. List out the types of presses used in sheet metal operations?
54
1. What is the process involved in making internal gears?
2. What are the various forces involved in rolling process?
3. Write any four disadvantages of Hot working process?
4. What are the operations used for making a compound die?
5. What is the process used for making the parts of circular cross-section which are symmet-
rical about the axis of rotation
6. What are various types of rolling mills?
55
LAB-11 STUDY OF COMPOUND DIE
12.1 AIM
To study a Compound tool and perform blanking and piercing operations. To determine the
punching force and blanking force theoretically and compare the same with obtained readings.

Hydraulic Press

Compound tool, Clamps and Blank..
12.4 SPECIFICATIONS
1. Capacity: 25 tons
2. Distance between columns: 865x300 mm2
3. Distance between ram to bed: minimum 180mm and maximum 915mm
4. Travel of ram: 180mm
5. Power of motor: 5 H.P.
12.5 THEORY
Press working may be defined as a chip less manufacturing process by which various com-
ponents are made from sheet metal. This process is also termed as cold stamping. The process
has got the following advantages:
Small weight of fabricated parts.
1. High productivity of labour.
2. High efficiency of technique as regards the fabrication of items of diversified shapes, both
simple and complex, such as washers, bushings, retainers, of ball bearings, tanks and car
bodies etc.
3. The parts obtained by cold sheet metal working are distinguished for their size accuracy.
In many cases, they require no subsequent machining and are delivered to the assembly
shop.
56
PRESSES: These are classified in various ways:
1. Source of power.
2. Method of actuation of the rams
3. Number of slides
4. Type of frame
5. The type of work for which the press has been designed.
Source of power: Two kinds of sources of power for applying force to the ram are mechanical
and hydraulic.
In Mechanical Presses the energy of flywheel is utilized which is transmitted to the work
piece by gears, cranks, eccentrics or levers. The flywheel rotates freely on the crankshaft and
is driven from an electric motor through gears or V belts. The motor runs continuously and
stores energy in the fly wheel. When the operator presses a foot treadle or actuates a button,
the clutch gets engaged and the fly wheel is connected to the crank shaft. The crankshaft starts
rotating and the stored up energy in the flywheel is transmitted to its ram on its downward
stroke .The clutch to engage and disengage the flywheel to the driveshaft can be : a jaw clutch,
an air operated clutch or an electromagnetic clutch. In manually operated mechanical presses,
the clutch is engaged after each cycle. But in automatic presses in which the metal strip is fed
to the die automatically, there is no need of single stroke clutch disengaging mechanism and the
ram moves up and down continuously.
These presses can be classified as plain and geared . In the first design, the flywheel is mounted
directly on the driveshaft .On a geared press, the flywheel is carried on an auxiliary shaft which
is connected to the main shaft through one or more gear reductions, depending upon size and
57
energy needed. In this arrangement, the flywheel stores considerably more energy than the plain
drive as its speed is higher than main drive shaft.
In hydraulic press, the ram is actuated by oil pressure on a piston in a cylinder. Mechanical
presses have following advantages over the hydraulic press:
1. Run faster
2. Lower maintainance cost
3. Lower capital cost.
Advantages of Hydraulic presses are:
1. More versatile and more easy to operate.
2. Tonnage adjustable from zero to maximum.
3. Constant pressure is maintained through out the stroke.
4. Force and speed can be adjusted through out the stroke.
5. More powerful than Mechanical presses.
6. Safe as it will stop at pressure setting.
The main disadvantage of Hydraulic press is that it is slower than a Mechanical press.
A press is rated in tones of force, t is able to apply without undue strain . To keep the deflections
small, it is a usual practice to choose a press rated 50 to 100% higher than the force required
for an operation.
Press selection: The factors which should be considered while selecting a press for a given
job are: the overall work size, the stock thickness and material, kind of operation to be per-
formed, power required and speed of operation.
For punching, blanking and trimming operations, usually the crank or eccentric type me-
chanical press is used. This is due to their small working strokes and high production rates. In
these operations, there is sudden release of load at the end of cutting stroke. This sudden release
of load is not advisable in Hydraulic presses. So, Hydraulic presses are not preferred for these
operations .If however these are inevitable, and then some damping devices are incorporated
in press design. For coining and other squeezing operations, which require very large forces,
knuckle joint mechanical press is ideally suited. Hydraulic presses, which are slower and more
powerful, can also be used for these operations. Hydraulic presses are also better adapted to
pressing, forming and operations, which are basically slower processes. Press Working Ter-
minology: A simple cutting die used for punching and blanking operations is shown in fig. the
following are the main components of die and press.
58
Bed: The bed is the lower part of a press frame that serves as a table to which a bolster plate
is mounted.
Bolster Plate: This is a thick plate secured to the press bed, which is used for locating
and supporting the die assembly. It is usually 5 to 12.5 cm thick.
Die set: It is unit assembly which incorporates a lower and upper shoe, two or more guide
posts and guide post bushings.
Die: The die may be defined as the female part of a complete tool for producing work in a
press. It is also referred to a complete tool consisting of a pair of mating members for producing
work in a press.
Die Block: It is a block or a plate which contains a die cavity. Lower Shoe: The lower
shoe of a die set is generally mounted on the bolster plate of a press. The die block is mounted
on the lower shoe. Also, the guide posts are mounted in it. It is also called as die holder.
Punch: This is the male component of the die assembly, which is directly or indirectly
moved by and fastened to the press ram or slide.
Upper shoe: This is the upper part of the die set which contains guide post bushings. It is
also called as punch holder because the punch is mounted on it. Punch plate: The punch plate
or punch retainer fits closely over the body of the punch and holds it in proper relative position.
Back up plate: Back up plate or pressure plate is placed so that the intensity of pressure
does not become excessive on punch holder .The plate distributes the pressure over a wide area
and the intensity of pressure on the punch holder is reduced to avoid crushing.
Stripper: It is a plate which is used to strip the metal strip from a cutting or non cutting
punch or die. It may also guide the sheet.
Knockout: It is a mechanism, usually connected to and operated by the press ram, for
freeing a work piece from a die.
Pitman: It is a connecting rod which is used to transmit motion from the main drive shaft
to the press slide.
Shut height: It is the distance from top of the bed to the bottom of the slide, with its
stroke down and adjustment up.
Stroke: The stroke of a press is the distance of ram movement from its up position to its
down position. It is equal to twice the crankshaft throw or eccentric drives but is variable on
the hydraulic press. STUDY OF COMPOUND DIE
59
In these dies two or more operations may be performed at one station. Such dies are considered
as cutting tools since only cutting operations are carried out. Compound dies are more accurate
and economical in mass production as compared to single operation dies.
Cutting forces: In cutting operation as the punch in its downward movement enters the
material it need not penetrate the thickness of the stock in order to affect complete rupture of
the part. The distance which the punch enters in to the work material to cause rupture to take
place is called “penetration” and is usually given as percentage of the stock thickness. The %
penetration depends on the material being cut and also on the stock thickness. When a hard and
strong material is being cut very little penetration of the punch is necessary to cause fracture.
With softer the penetration will be greater. The percentage penetration is also depends upon
the stock thickness, being smaller for thinner sheets.
The max force Fmax in newtons needed to cut a material is equal to the area to be sheared
times the shearing strength, Ts in N/mm*2 for the material. For a circular blank of diameter
D mm and of thickness t mm the cutting force will be given as: Fmax= π Dt τs = P t τs .
Where P is the perimeter of the section to be blanked For rectangular blanks the length L
and width b it is Fmax= 2(L+b) t τs .
12.6 PROCEDURE
Component to be produced:
60
3. Place the blank of required size between the die and punch.
4. Apply pressure hydraulically on the blank through the punch so that piercing will takes
place at the first station.
perform the piercing operation.
6. Move the blank in forward direction until it touches the stopper on the die.
7. Again apply pressure hydraulically on the blank so that piercing punch blanks out a
portion of the metal in which already two holes had been pierced. At the same time
piercing operation takes place at the first station.
perform the piercing and blanking operations.
9. Difference of the two readings gives the force required to perform blanking operation.
10. Compare the values with the theoretically obtained values.
11. The process may be repeated to produce the components in mass production.
OBSERVATIONS & CALCULATIONS: Force required to perform blanking and pierc-

ing operations
Maximum force needed to cut material is Fmax = P. t. τs .
Where P is the Perimeter of the blank
t is the thickness of the blank
τs . is the shear strength of the material.
12.7 Precautions
1. The die should be properly clamped to the bed of the machine and it is not disturbed
during the process.
2. The punch is properly fixed to the ram of the machine.
61
3. The load should be applied uniformly on the blank.
4. The ram should be fed slowly towards the die and make sure that it is properly in line
with the die.


rical about the axis of rotation
62
LAB-12 DRAWING AND BENDING
13.1 AIM
1. To Determine the Blank Size, Drawing Force and Blank Holding Force for Producing a
symmetrical cup of circular cross section using a Draw Tool and Perform Drawing Oper-
ation.
2. To perform Bending Operation
13.2 EQUIPMENT AND TOOLS REQUIRED

Hydraulic Press, Draw tool and Inclinometer.

Aluminium sheet of required size and MS round bar of 25mm diameter.
13.4 THEORY
DRAWING: Drawing operation is the process of forming a flat piece of material into a hollow
shape by means of a punch which causes the blank to flow into the die cavity. The depth of
draw may be shallow, moderate or deep. If the depth of the formed cup is up to half of its
diameter, the process is called “Shallow drawing”. If the depth of the formed cup exceeds the
diameter it is termed as ”Deep drawing”. Parts of various geometries and sizes are made by
drawing operation, two extreme examples being bottle caps and automobile panels.
63
As the drawing progress i.e. as the punch forces the blank into die cavity, the blank diameter
decreases and causes the blank to become thicker at its outer portions. This is due to the cir-
cumferential compressive stress to which the material element in the outer portions is subjected.
If this stress becomes excessive the outer portions of the blank will have the tendency to buckle
or wrinkle. To avoid this, a pressure pad or blank holder is provided. The holding down of
pressure is obtained by means of springs, rubber pad, compressed air cylinder or the auxiliary
ram on a double action press.
The portion of the blank between the die wall and punch is subjected to nearly purely tension
and tends to stretch and becomes thinner. The portion of the formed cup which wraps around
the punch radius is under tension in the presence of bending. This part becomes the thinnest
portion of the cup. This action is termed as ’necking’ and in the presence of unsatisfactory
drawing operation, is usually the first place to fracture. The outer portions of the blank under
the blank holder become thicker during the operation. When these portions are drawn into
the die cavity, ’ironing’ of this section will occur if the clearance between the punch die is not
enough to accommodate this increased thickness of the work piece. This ironing is useful if
uniform thickness of the product is desired after the drawing operation.
DEEP DRAWBILITY: Deep drawability or drawing ratio of the metal is defined as the
ratio of the max blank diameter to diameter of the cup drawn from the blank, i.e. D/d. For a
given material there is a limiting drawing ratio (LDR), after which the punch will pierce a hole
in the blank instead of drawing the blank
64
This ratio depends upon many factors, such as material, amount of friction present etc. The
usual range of the max drawing ratio is 1.6 to 2.3.
A simple push through drawing die is shown. The drawing punch should be properly vented
with drilled passengers. Venting serves double purpose it eliminates suction which would hot the
cup on the punch and damage the cup when it is stripped from the punch. Secondly, venting
provides passages for lubricants. Many presses are used for the deep drawing operations are
hydraulically operated and these presses have an additional hydraulic cylinder and piston for
the additional slide.
Product applications of deep drawing process are: cups, shells, automotive bodies, gas tanks,
house hold hard ware etc.
REDRAWING: In deep drawing the percentage reduction in one draw is defined as: % re-
duction = [D-d)/D] X 100
Now D/d =1.6 to 2.3, d/D=0.435 to 0.625 = 0.5 (average) The average reduction in deep
drawing=
[1-d/D] X 100 = 50%
To make tall cups of smaller diameter it is necessary to use successive drawing operations.
Reducing the drawn cup to the smaller diameter and increased height is known as ”redrawing”.
BENDING: Bending is the metal working process by which a straight length is transformed
in to the curved length. It is a very common forming process for changing sheet and plate into
channels, drums, tanks etc. During the bending operation, the outer surface of the material is
in tension and the inside surface is in compression. The strain in the bent material increases
with decrease in the radius of curvature. The stretching of the bend causes the neutral axis of
the section towards the inner surface. In most cases the distance of the neutral axis to the inside
of the bend is 0.3t - 0.5t where t is the thickness of the part.
Bending terminology is illustrated in fig.
65
BENDING METHODS: The three bending methods commonly used are V-bending, edge bend-
ing, and U bending V-BENDING:
In V bending, a wedge shaped punch forces a metal sheet or strip in to a wedge shaped die
cavity .The bend angle may be acute, 900 or obtuse. As the punch descends the contact forces
at the die corner produces a sufficiently large bending moment at punch corner to cause the
necessary deformation.
To maintain the deformation to be plane - strain, the side creep of the part during its bending
is prevented or reduced by incorporating a spring loaded knurled pin in the die. The friction
between pin and the part will achieve this. Plane strain conditions will also be established in
the center of the sheet if its width is more than 10 time its thickness.
SPRING BACK At the end of the bending operation, when the pressure on the metal is
released, there is an elastic recovery by the material. This causes a decrease in the bend angle
and this phenomenon is termed as spring back For low carbon steel it can be 10 - 20 and for
medium carbon steel, it can be 30 - 40 for phosphorus bronze and spring steel can be 100 –
150 To compensate for spring back the wedge shaped punches and the mating dies are made
with included angles some what less than required in the formed component. Due to this the
component will be bent to a greater angle than desired but will spring back to the desired angle
for other types of bending the part is over bent by an angle equal to the spring back angle by
having the face of the punch undercut or relieved
66
Blank Size: One of the first jobs of the draw die designer is to find the size of the blank
to be used for making a given cup. It is often difficult to find a blank of exact size required
for making a given shell, because of thinning and thickening of sheet during drawing. The cal-
culation should be based on volume, surface area or by layout. The following gives the useful
relations in calculating the blank diameter for cylindrical shells for relatively thin materials.
Where r = corner radius on the punch, mm

h = height of the shell, mm
d = outer diameter of the shell,

mm D = blank diameter, mm Drawing Force The drawing force depends on the cup material,
its dimensions and the configuration. The drawing force can empirically be calculated using the
following equation for cylindrical shells.
Where P = drawing force, N

t = thickness of the blank material, mm
s = yield strength of the metal, Mpa
C = constant to cover friction and bending. Its value is between 0.6 and 0.7
Blank Holding Force: The blank holding pressure required depends on the wrinkling tendency
of the cup, which is difficult to determine and hence it is obtained more by trail and error. The
maximum limit is generally one-third of the drawing force.
OBSERVATIONS AND CALCULATIONS: Using above relations calculate,
1. r = corner radius on the punch = mm
h = height of the shell = mm
d = outer diameter of the shell = mm
d/r =
then D = blank diameter = mm
2. Drawing Force = N
3. Blank Holding Force = N
Drawing Operation:
3. Calculate the required blank size and place the same between the punch and die block.
67
4. Apply the hydraulic pressure on the punch through ram so that the punch slowly descends
on the blank and forces it take the cup shape formed by the end of the punch, by the it
reaches the bottom of the die.
5. When the cup reaches the counter bored portion of the die, the top edge of the cup formed
around the punch expands slightly due to spring back.
6. Observe the reading of the pressure gauge which directly gives the force required to perform
the operation.
7. Calculate the drawing force required, to perform the operation using above relations.
8. Compare the two readings
9. Then move the punch in the return direction so that the cup will be stripped by counter
bored portion.
Bending Operation
1. Fix the wedge shaped punch to the ram of the press.
2. Fix the wedge shaped die cavity on the bed of the press using clamps, bolts and nuts.
3. Place the MS round bar between the punch and die.
4. Apply pressure on the bar by moving the ram in downward direction through the punch.
5. As the punch descends, the contact forces at the die corner produce a sufficiently large
bending movement at the punch corner to cause the necessary deformation.
6. Then the bar will take the shape of die cavity.
7. Measure the included angle of the bar using inclinometer and repeat the process until the
included angle reaches 900
13.5 Precautions

68
rical about
6. the axis of rotation
69
LAB-13 INJECTION MOULDING (AIR TIGHT BOTTLE CAP)
14.1 AIM
To Make an Air Tight Bottle Cap by Using Injection Moulding.
14.2 EQUIPMENT AND TOOLS REQUIRED

Die, injection-moulding equipment.

Plastic pellets
14.4 THEORY
Plastics: Polymers can be divided into three broad divisions: plastics, fibers and elastomers
(polymers of high elasticity, for example, rubber). Synthetic resins are usually referred to as
plastics. Plastics derive their name from the fact that in a certain phase of their manufacture
they are present in a plastic stage (that is acquire plasticity), which makes it possible to impart
any desired shape to the product. Plastics fall into a category known chemically as high poly-
mers.
Thus Plastics is a term applied to compositions consisting of a mixture of high molecular

compounds (synthetic polymers) and fillers, plasticizers, stains and pigments, lubricating and
other substances. Some of the plastics contain nothing but resin (for instance, polyethylene,
polystyrene).
Types of Plastics: Plastics are classified on the broad basis of whether heat causes them to
set( thermosetting) or causes them to soften and melt(thermoplastic).
Thermosetting Plastics: These plastics undergo a number of chemical changes on heat-
ing and cure to infusible and practically insoluble articles. The chemical change is not reversible.
Thermosetting plastics do not soften on reheating and cannot be reworked. They rather be-
come harder due to completion of any left over polymerization reaction. Eventually at high
temperatures, the useful properties of the plastics get destroyed. This is called degradation.
The commonest thermosetting plastics are: alkyds, epoxides, melamines, polyesters, phenolics
and ureas.
Thermoplastic Plastics: These plastics soften under heat, harden on cooling, and can be
resoftened under heat. Thus they retain their fusibility, solubility and capability of being re-
peatedly shaped. The mechanical properties of these plastics are rather sensitive to temperature
and to sunlight and exposure to temperature may cause thermal degradation. Common ther-
moplastics are: acrylics, poly tetra fluoro ethylene (PTFE), polyvinyl chlorides (PVC), nylons,
polyethylene, polypropylene etc.
70
Properties:
1. Their comparatively low density( 1- 2 g/cm ), substantial mechanical strength, higher

strength to weight ratio and high anti friction properties have enabled plastics to be effi-
ciently used as substitute for metals, for example, non –ferrous metals and alloys-bronze,
lead, tin, babbit etc.
2. With certain special properties (silent operation, corrosion resistance etc), plastics can
sometimes replace ferrous metals.
3. From the production point of view, their main advantage is their relatively low melting
points and their ability to flow into their moulds.
4. Simple processing to obtain machine parts
5. In mass production plastics substituted for ferrous metals allow the production costs to
be reduced by a factor 1.5 to 3.5 and for non – ferrous metals by a factor of 5 to 20.
6. Good damping capacity and good surface finish of the product.
7. The high heat and electric insulation of plastics permits them to be applied in the radio
and electrical engineering industries as dielectrics and as substitutes for porcelain, ebonite,
shellac, mica, natural rubber, etc.
8. Their good chemical stability, when subjected to the action of solvents and certain oxidizing
agents, water resistance, gas and steam proof properties, enable plastics to be used as
valuable engineering materials in the automobile and tractor, ship building and other
industries
Disadvantages:
1. Comparatively higher costs of materials.
2. Instability of most plastics to withstand even moderately high temperatures.
Processing of Thermoplastic Plastics: The common forms of raw materials for process-
ing plastics into products are: Pellets, Powders, Sheet, Plate, and Tubing. Liquid plastics are
used especially in the fabrication of reinforced plastic parts.
Thermoplastics can be processed to their final shape by moulding and extrusion processes.
However, extruding is often used as an intermediate process to be followed by other processes
for example vacuum forming or machining.
Injection Moulding: An important industrial method of producing articles of thermoplastics
is Injection Mouilding (shown in fig.). The process is essentially as follows:
71
The moulding material is loaded into a hopper from which it is transferred to a heating section
by a feeding device, where the temperature is raised to 1500C – 3700C and pressure is built
up. The material melts and is forced by an injection ram at high pressure through a nozzle and
sprue into a closed mould which forms the part. The mould is in at least two sections, so that
it may be split in order to eject the finished component. For the process to be competitive the
mould must be fairly cool (between ambient temperature and the softening point of the plastic)
and consequently the mould must be cooled by circulating water.
The improvement to the ram type injection moulding machine lies in the separation of the plas-
ticizing and filling actions. The single – screw pre-plasticizer is probably the most successful
design for injection moulding machines (shown in fig).The rotation of the screw provides the
plasticizing action by shearing and frictional effects and the axial motion of the screw provides
the filling action.
Injection moulding machines have a high production capacity: some can produce from 12 to
16 thousand parts per shift. This method is suitable for making parts with complex threads
72
and intricate shapes, thin-walled parts etc. Typical parts include: Cups, containers, housings,
tool handles, toys, knobs, plumbing fittings, electrical and communication components such as
telephone receivers etc. Injection moulding machines range in size from an injection capacity of
12,000 mm3 to 2.2 x 106 mm3. The injection pressure may range from 100-150 MPa.
14.5 PROCEDURE
1. The pellet form of plastic is introduced into the container through hopper.
2. The plastic pellet enters into the container. The container is heated with the coil, which
is wounded around it.
3. The plastic of powder form is converted into molten stage at a temperature of 800 C.
4. The die is placed exactly below the nozzle of the container.
5. The melted plastic is injected into the die with the help of lever arm and it is allowed to
solidify say for about one minute.
6. Then retract the lever arm slightly and open the mould.
7. Then eject the mould piece of the required shape from the die
14.6 Precautions
1. The material should not be heated rapidly.
73
2. The die should be placed exactly below the nozzle.
3. Proper temperature should be maintained while heating the plastic

1. 1. Explain forward and back ward extrusion.
2. Discuss the process of impact extrusion
3. What are the advantages of hydrostatic extrusion?
4. Explain manufacture of seamless tubes by extrusion process.
5. Compare hot and cold extrusion.
6. How do you find the forces in extrusion operation?

1. Explain tube and pipe extrusion process.
2. Discuss defects in extrusion.
3. Discuss factors for die design in extrusion.
4. What are the lubricants used in extrusion processes?
5. What are various types of hammers and presses?
6. Explain advantages and limitations of swaging.
74
LAB-14 PLASMA ARC WELDING
15.1 AIM
To Join two given work pieces using plasma arc welding and Brazing and cut the given plate
into two parts using plasma cutting.
15.2 Apparatus required:

Plasma Arc Welding System Material Required: MS flat 50x50x10 mm – 3 Nos
15.3 PROCEDURE
1. The edge of the given material is prepared to the required V-shape using grinding machine.
2. The machine is set to the required parameters( For Welding).
work pieces.
5. First run of welding is done to fill the gap and penetration of the weldment by holding
the electrode at about 700 and filler rod at 300 and move the electrode to another end
uniformly.
6. Second run of welding is done with proper weaving and uniform movement so that a
uniform weld bead will be obtained.
8. Filing is done to remove any spatter around the weld.
15.4 Precautions
1. The material should not be heated rapidly.
2. The die should be placed exactly below the nozzle.
3. Proper temperature should be maintained while heating the plastic.
75
1. What is the use of flux in welding?
2. Write a short note on butt welding.
3. List out minimum six types of welding process.
4. Write a short note on the symbol of weld?

3. Write the constituents of electrode coating with their functions.
4. What is heat shrinkage in spot welding?
5. What is the effect of clearance in brazing?
76

ME MP Lab Manual1-Merged

Uploaded by

Copyright:

Available Formats

ME MP Lab Manual1-Merged

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ME MP Lab Manual1-Merged

Uploaded by

Copyright:

Available Formats

INSTITUTE OF AERONAUTICAL ENGINEERING

MANUFACTURING PROCESSES LABORATORY (AMEB06)

DEPARTMENT OF AERONAUTICAL ENGINEERING

2 LAB-1 ARC WELDING (V-BUTT JOINT) 4

3 LAB-2 ARC WELDING (LAP JOINT) 10

4 LAB-3 SPOT WELDING (LAP JOINT) 14

5 LAB-4 TUNGSTEN INERT GAS (TIG) WELDING 18

6 LAB-5 PATTERN DESIGN AND MAKING 22

7 LAB-6 PATTERN DESIGN AND MAKING 27

8 LAB-7 SAND PROPERTIES TESTING 33

9 LAB-8 CASTING FOR A SOLID PATTERN 36

11 LAB-10 STUDY OF PROGRESSIVE DIE 48

12 LAB-11 STUDY OF COMPOUND DIE 56

13 LAB-12 DRAWING AND BENDING 63

14 LAB-13 INJECTION MOULDING (AIR TIGHT BOTTLE CAP) 70

15 LAB-14 PLASMA ARC WELDING 75

1.1.1 Student Responsibilities

1.1.2 Responsibilities of Faculty Teaching the Lab Course

1.1.4 Course Coordinator Responsibilities

1.2 Lab Policy and Grading

ATTENDANCE: Attendance is mandatory as per the academic regulations.

LAB RECORD’s: The student must:

2. Keep all work in preparation of and obtained during lab.

3. Perform the experiment and record the observations in the worksheets.

Pre-Requistes and Co-Requisties:

1.3 Course Goals and Objectives

More explicitly, the class objectives are:

1. Understand the Pattern design and making, casting drawing.

3. Demonstrate practical understanding Moulding,melting and casting

4. Demonstrate practical understanding of ARC welding lap and butt joint

5. Demonstrate practical understanding of Spotwelding, TIG welding

6. Demonstrate practical understanding of brazing

9. Understand the Bending and other operation

10. Demonstrate practical understanding Injection moulding process

11. Demonstrate practical understanding Blow moulding process

1.4 Use of Laboratory Instruments

1.4.1 Instrument Protection Rules

1.5 Data Recording and Reports

2.2 APPARATUS REQUIRED

2.3 MATERIAL REQUIRED

An electric arc for welding is obtained in the following ways:

Electric Arc Welding

Selection of Welding Joint

1. Base plate thickness

4. Type of loading, i.e. tension, shear, impact, bending etc..

8. Chances and magnitude of distortion

2. The machine is set to the required current (75 amps).

7. The scale formed is chipped with chipping hammer.

8. Filing is done to remove any spatter around the weld

3. Ensure proper insulation of the cables and check for openings.

2.7 Pre Lab Viva Questions

2. Define cope, drag and cheek?

3. Define refractoriness of the sand material?

4. Define flow ability or the sand material?

5. Define dry strength or the sand mould?

2.8 Post Lab Viva Questions

5. What is the function of a core? What are core prints?

3.2 APPARATUS REQUIRED