me2207 - manufacturing technology laboratory-i

MANUFACTURING TECHNOLOGY – I

LABORATORY Manual

EX.NO. DATE TITLE OF EXPERIMENT MARKS SIGNATURE

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3

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5

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15

FOUNDRY

1. Introduction

2. Mould with solid gear pattern

3. Mould with split (Dumble) pattern or stepped cone pulley

4. Mould with loose piece pattern or flange pattern

5. Mould with core or V grooved pulley

WELDING

1. Introduction

2. Horizontal position welding

3. Vertical position welding

4. Over head welding

5. Gas welding

SHEET METAL WORK

1. Introduction

2. Tray

3. Funnel

LATHE WORK

1. Introduction

2. Machining a work piece by facing, plain turning and step turning operation by using lathe

3. Machining a work piece by single start V-thread and knurling operation by using a lathe

4. Machining a work piece by taper turning operation (compound rest method) by using a lathe

5. Machining a work piece by multi start V-thread cutting operation by using a lathe

6. Machining a work piece by boring internal thread cutting operation by using a lathe

FOUNDRY

SAFETY PRECAUTIONS

Watch your steps or otherwise you may spoil the mould on the floor.

Do not wear rings and watches while coming on the shop.

While preparing the mould sleep your tears on your right hand side.

Be careful when flooring the molten metal otherwise you may split the molten metal to

yourself and others vice.

Approach skilled people to have your dust cleaned.

Casting is manufacturing process which may be defined as pouring at molten metal into

mould.

The place where castings are made is called foundry.

The mould material is usually sand but metal can also used to low temperature melting alloys.

The sand is generally used for molding is mixture at river sand and clay.

EXERCISE-1

DATE:

MOULDING WITH SOLID GEAR PATTERN

AIM:

To prepare a sand mould using a Gear Pattern.

MATERIALS REQUIRED:

Moulding sand

Parting sand

Facing sand

TOOLS REQUIRED:

Trowel

Rammer

Strike off bar

Lifter

Runner

Raiser

Gate cutter

Vent wire

Draw spike

Swap

Riddle

Sprue pin

Bellow

Moulding box

PROCEDURE:

1. Place the moulding board on a horizontal surface

2. The mould box, pattern, tools and the table / floor are cleaned.

3. A suitable core is prepared with core box or with pattern

4. The drag is placed over the moulding board and one half of the pattern is placed centrally in

the drag.

5. The thin layer of parting sand is filled around the pattern, to prevent the mould sand to stick to

the board surface.

6. Green sand is fitted around the pattern with a trowel and ramming is done uniformly using a

hand rammer

7. The process of adding the green sand and ramming is continued until the sand completely fills

the drag box

8. The excess sand is leveled off with a strike-off bar and vent holes are provided using vent

wires

9. The drag box is now rolled over exposing the pattern

10. The surface of the sand is first smoothened with a trowel and then covered with dry parting

sand

11. The cope is placed exactly over the drag using the dowel pins. The other half of the pattern is

placed over the first half with dowel pins. The sprue and the riser pins are placed in position.

12. Filling the green sand, uniform ramming and leveling is done similar to that in the drag

13. The sprue and riser pins are withdrawn and the cope is rolled over to horizontal position

14. Any loose sand is brushed and water from swab is sprinkled on the sand around the pattern.

15. A draw spike is driven into both the halves and rapped lightly to loosen the patterns. Now the

patterns are withdrawn by lifting the draw spike

16. Gate is cut in the drag using gate cutter and the cope is placed in correct position

17. The green sand mould of the split pattern is ready for pouring the molten metal

RESULT:

Thus the mould of the given gear pattern is obtained.

EXERCISE-2

DATE:

MOULDING WITH SPLIT (DUMBLE) PATTERN

AIM:

To make the mould for the given split (Dumble) Pattern.

MATERIALS REQUIRED:

Moulding sand

Parting sand

Facing sand

TOOLS REQUIRED:

Trowel

Rammer

Strike off bar

Lifter

Runner

Raiser

Gate cutter

Vent wire

Draw spike

Swap

Riddle

Sprue pin

Bellow

Moulding box

PROCEDURE:

1. Place the moulding board on a horizontal surface


3. A suitable core is prepared with core box or with pattern

4. The drag is placed above the moulding board. Now the pattern is kept at center of the drag.

5. Now the parting sand is sprinkled before we keep the pattern.

6. Facing sand is sprinkled over the pattern to a depth of 5mm, and then green sand filled over it.

7. Proper ramming is done on the green sand to get a air tight packing and excess sand is

removed by strike off bar.

8. The drag box is inverted upside down, and the cope box is placed over the drag box and

locked.

9. The riser pin and sprue pin placed at right position and green sand is filled over the pattern.

10. Proper ramming is done on the green sand to get air tight packing with strike off bar leveling

is done.

11. Now riser pin and sprue pin get removed from the green sand mould.

12. The pattern is removed by draw spike tool.

13. Gate is prepared using gate cutter and core is placed vertically inside the cavity.

14. The vent holes are made with vent wire on the cope.

RESULT:

Thus the mould of the given stepped cone pulley is obtained.

EXERCISE-3

DATE:

MOULDING WITH LOOSE PIECE PATTERN

AIM:

To make the mould for the given loose piece pattern.

MATERIALS REQUIRED:

Moulding sand

Parting sand

Facing sand

TOOLS REQUIRED:

Trowel

Rammer

Strike off bar

Lifter

Runner

Raiser

Gate cutter

Vent wire

Draw spike

Swap

Riddle

Sprue pin

Bellow

Moulding box

PROCEDURE:

1. The pattern is placed on the moulding board, with its flat side on the board.


3. The drag box is placed over the board, after giving it a clay wash inside.

4. Parting sand is sprinkled over the pattern and the moulding board.

5. Foundry sand is placed over the pattern, until it is covered to a depth 20mm to 30mm.

6. Using fingers, sand is packed around the pattern and into the corner of the box.

7. Some more sand is then placed in the box and packed with the rammer, using first, the

peen end and then with the butt end.

8. The excess sand from the top surface of the drag is removed by striking-off with the

strike-off bar.

9. The drag is turned upside down.

10. The loose sand particles are blown-off with the bellows and the surface is smoothened.

11. The cope box is placed in position on top of the drag box, after giving it a clay wash

inside. The riser pin is then located on the surface of the pattern.

12. The sprue pin is placed at about 50mm to 60mm from the pattern, but on the opposite side

of the riser pin.

13. Parting sand is sprinkled on the upper surface.

14. Steps 5 to 8 are repeated appropriately.

15. Using a vent rod, holes are made to about 10mm from the pattern.

16. The sprue and riser pins are removed, by carefully drawing then out. A funnel shaped

hole is made at the top of the sprue hole, called pouring basin/cup.

17. The cope is lifted and placed aside on its edge.

18. A draw spike is inserted into the pattern and the edges around the pattern are wetted.

Then the pattern is loosened by tapping, and then drawn straight up.

19. The mould is repaired by adding bits of sand, wherever the mould is found deflective.

20. Using a gate cutter, a gate is cut in the drag, from the spure to the mould.

21. The loose sand particles that are present in the mould are blown-off.

22. The mould is finally closed by replacing the cope on the drag and placing weights on it.

RESULT:

Thus the mould of the given flange pattern is obtained.

EXERCISE-4

DATE:

MOULDING WITH CORE PATTERN

AIM:

To make the mould for the given core pattern.

MATERIALS REQUIRED:

Moulding sand

Parting sand

Facing sand

TOOLS REQUIRED:

Trowel

Rammer

Strike off bar

Lifter

Runner

Raiser

Gate cutter

Vent wire

Draw spike

Swap

Riddle

Sprue pin

Bellow

Moulding box

PROCEDURE:


2. The moulding box is selected and the drag part is placed upside down on the

moulding board.

3. The pattern for this mould is the V-Grooved pulley which is a spilt pattern. So keep

one part of the pattern on the board inside the box in such a way that ample space is

lift for sprue and getting and is filled with sand.

4. The excess sand is removed using strike off bar. Then the drag is rolled over sprinkle

the parting sand over the drag and keeps the core box and fixes it using dowel pins.

5. Fix the other half of the pattern, sprue pin and the core box is filled with the sand and

rammed without affecting the set up. After that the sprue pin and riser pins are

withdrawn using draw spike and vent holes are made in the moulding using vent wire.

6. The cope is removed and the pattern is removed carefully using draw spike and

mallet. The sprue basin and the getting are made using tools for the flow of molten

metal into the cavity.

7. The cavity is cleaned and sprayed with the parting sand for easy removal of the object

after casting. The cope is again placed over the drag correctly and is locked using

dowel pins.

8. Now the mould is ready for casting. After pouring the molten metal and solidification

remove the casting from the mould. The V-Grooves can be made at the periphery by

removing the unwanted material in a lathe.

RESULT:

Thus the mould is made for the given core pattern.

WELDING

SAFETY PRECAUTIONS FOR WELDING

Always weld in a ventilated place.

Do not weld around combustible or inflammable materials, where sparks may cause a fire.

Never weld containers which have been used for storing gasoline, oil or similar materials,

without first having them thoroughly cleaned.

ARC WELDING

Chuck the ground connection and insulation of all the wires.

The arc should be observed only through a shield or goggles.

Always wear the safety hand gloves, apron and leather shocs.

Prevent welding cables from coming in contact with hot metal, water, oil or grease. Avoid

dragging the cables around sharp corners.

Always turn off the machine when leaving the work.

Remove the slag by chipping hammer only.

Apply eye drops after welding is over for the day, to relieve the strain on the eyes.

GAS WELDING

Always wear welding goggles while doing gas welding.

Always use the spark lighter to light the torch, never use a match.

Do not allow blow pipe to heat cylinders, hoses or any other equipment.

Do not allow the hose to become excessively warm.

Secure cylinders in use, against falling, which may knock – off the valve.

Gaggle, face shields and gloves must be used while welding.

Any repairable parts of the welding equipment should be sent to the manufacturer for

necessary repairs.

EXERCISE-5

DATE:

HORIZONTAL POSITION BUTT JOINT WELDING

AIM:

To join two given metal plates by a V-Butt joint arc welding in horizontal position welding.

MATERIAL REQUIRED:

Two mild steel plates

TOOLS REQUIRED:

Welding transformer

Safely gloves

Chipping hammer

Tongs

Electrodes

Hand shield

Flat file

Wire brush

PROCEDURE:

1. The given work pieces are thoroughly cleaned of rust, scale and other foreign materials.

2. The electrode is fitted in the electrode holder and the welding current is set to a proper value.

3. The electric arc produced melts the welding rod and join the two metal plates, maintains a gap

of 3mm between the plate and welding rod.

4. When current is passed, arc is produced between the electrode and work piece. Here the

welding should be carried out on both sides.

5. As soon as the welding process is finished, switch of the current supply and allow the work

piece to cool.

6. The slag formation on weld is removed by using a chipping hammer.

7. Finally using wire brush, welded portions are cleaned.

RESULT:

Thus the required butt joint is obtained by arc welding.

EXERCISE-6

DATE:

VERTICAL POSITION BUTT JOINT WELDING

AIM:

To join two given metal plates by a V-Butt joint arc welding in vertical position welding.

MATERIAL REQUIRED:


TOOLS REQUIRED:

Welding transformer

Safely gloves

Chipping hammer

Tongs

Electrodes

Hand shield

Flat file

Wire brush

PROCEDURE:








piece to cool.



RESULT:

Thus the required vertical position is obtained by arc welding.

EXERCISE-7

DATE:

OVER HEAD BUTT JOINT WELDING

AIM:

To join two given metal plates by a V-Butt joint arc welding in over head welding.

MATERIAL REQUIRED:


TOOLS REQUIRED:

Welding transformer

Safely gloves

Chipping hammer

Tongs

Electrodes

Hand shield

Flat file

Wire brush

PROCEDURE:








piece to cool.



RESULT:

Thus the required overhead is obtained by arc welding.

EXERCISE-8

DATE:

GAS WELDING

AIM:

To join the given two work pieces as a required type of joint by gas welding.

MATERIAL REQUIRED:


Oxygen and acetylene gas cylinders with pressure regulators and pressure gauges.

TOOLS REQUIRED:

Gas welding torch

Filler rod

Gloves and apron

Safety goggle

Chipping hammer

Wire brush

PROCEDURE:


2. The joining work pieces are positioned properly.

3. Acetylene and oxygen cylinder valves are opened then the acetylene torch valve is opened.

4. Light the tip of torch using lighter.

5. Oxygen and acetylene torch are adjusted and the required flame is obtained.

6. The welding torch and filler rod are moved along the line of weld and welding is done by

maintaining 3mm gap between plate and inner core of flame.

RESULT:

Thus the required welding is obtained by gas welding process.

SHEET METAL WORK

SAFETY PRECAUTIONS:

Loose clothing should be avoided.

Tools should always be kept in good working condition.

Use hand leather gloves while handling heavy sheets.

Avoid feeling the cut portion by hand while cutting with snip.

Do not let sheet metal slip through your hands. Most cuts from sheet metal result from

allowing it to slide through the hands.

EXERCISE-9

DATE:

SQUARE TRAY

AIM:

To make a tray out of the given sheet with specified dimensions.

MATERIALS REQUIRED:

Tin or Galvanized Iron sheet.

TOOLS REQUIRED:

Bench vice Divider Hand shearing Try square Snip Dot punch Steel rule Mallet Scribe Ball peen hammer

PROCEDURE:

1. The size of the given sheet is chucked with the steel rule.2. The layout of the tray is marked on the given sheet.3. The layout of the tray is cut by using the straight snip.4. Folding is done as per the given order using mallet and stake.5. Bending is done as per the given dimensions using the stake and mallet.6. Finally, the tray is riveted using the given rivets and hammer.

RESULT:

Thus the required tray is finished from the given sheet metal.

EXERCISE-10

DATE:

FUNNEL

AIM:

To make a funnel from the given sheet metal.

MATERIALS REQUIRED:

Tin or Galvanized iron sheet

TOOLS REQUIRED:

Bench vice Divider Hand shearing Try square Snip Dot punch Steel rule Mallet Ball peen hammer

PROCEDURE:

1. The size of the given sheet metal is chucked for its dimensions using steel rule.2. The required development of surface is being made on the white paper, which is overlapped

on the sheet metal.3. The marking is done on the sheet metal as pre the development being done on the paper.4. Now using straight snips, unwanted materials are removed.5. Now fold and bend the work piece to make the funnel shape and joint is made on the work

pieces.6. Then using grooves, locked grooved joint is made for about 5mm. Also, hemming is done in

the bottom of the funnel.7. In between top face and bottom face, butt joint is made using solder.8. Finally, trimming and finishing operations are being carried out.

RESULT:

Thus the funnel with required dimensions is made from the given sheet metal.

LATHE WORK PRACTICE

SAFETY PRECAUTIONS:

Do not attempt to operate a lathe unit you know the proper procedure and have been checked out on its safe operation by your instructor.

Never attempt to operate a lathe while your senses are impaired by medication or other substances.

Dress appropriately. Remove any necklaces or other dangling jewelry, wristwatch or rings, secure any loose- fitting clothing and roll up long sleeves. Wear an apron or a properly fitted shop coat.

Clamp all work solidly. Use the correct size tool and work handling device for the job. Get help when handling large sections of metal, heavy chucks and attachments.

Check work frequently when it is being machined between centers. A work piece expands as it heats up from friction and could damage the tailstock center.

Be sure all guards are in place before attempting to operate the machine. Never attempt to defeat or bypass a safety switch.

Turn the faceplate or chuck by hand to be sure there is no binding or danger of the work striking any part of the lathe.

Keep the machine clear of tools, and always stop the machine before making measurements and adjustments.

Metal chips are sharp and can cause severe cuts. Do not try to remove them with your hands when they become “stringy” and build up on the tool post. Stop the machine and remove them with pliers.

Do not run the cutting tool into the chuck.

Avoid talking to anyone while running the lathe. Do not permit anyone to fool around.

EXERCISE-11

DATE:

MACHINING A WORKPIECE BY FACING, PLAIN TURNING AND STEP TURNING OPERATIONS USING A LATHE

AIM:

To perform the facing, plain turning and step turning operation on the given work piece as per the given dimensions.

MATERIAL REQUIRED:

Mild steel rod

TOOLS REQUIRED:

Lathe machine Cutting tool Chuck key Steel rule Tool post key Vernier caliper Turning tool

PROCEDURE:

1. The dimension of the given work pieces are chucked by vernier caliper.2. The work piece is held in the lathe chuck properly and it is tightened by chuck key.3. The single point cutting tool is held in the tool post and it is tightened by tool post key.4. Facing is done with cutting tool moving from the centre of work piece towards outside. It is

done until the required length of the job is obtained.5. The turning operation is done with cutting tool to reduce the diameter up to the required

dimension for the two steps of various diameters.6. The work piece from the chuck is removed and the dimensions are chucked for the

requirements.

RESULT:

Thus the given work piece is facing, plain turning and step turning operations are as per the given dimensions by using lathe.

EXERCISE-12

DATE:

MACHINING A WORKPIECE BY TAPPER TURNING OPERATIONS

(COMPOUND REST METHOD) USING LATHE

AIM:

To perform taper turning operation on the given work piece as per the given dimensions.

MATERIAL REQUIRED:

Mild steel rod

TOOLS REQUIRED:

Lathe Steel rule Vernier caliper Cutting tool Scriber Chuck key Tool post key

PROCEDURE:

1. The dimension of the given work piece are chucked by vernier caliper.2. The work piece is held in the lathe chuck properly and it is tightened by chuck key.3. The single point cutting tool is held in the tool post and it is tightened by tool post key.4. Facing is done with cutting tool moving from the centre of work piece towards outside. It is

done until the required length of the job is obtained.5. Turning is done to reduce the diameter of the job. Sufficient depth of cut is given and it is

done until the required diameter of the job is obtained.6. The tapper turning operation is done on work piece according to the tapper angle calculated.

Taper angle is calculated by using the formula is given below. Taper angle, α = tan-1{(D-d) / 2L}

7. The compound rest is set at the calculated taper angle, for this the tool is moved by 450 to the

lathe axis. The taper turning is carried out using compound rest.

8. Finally, the finished job is inspected and unloaded from the chuck.

RESULT:

Thus the required size and shape of the given work piece is obtained.

EXERCISE-13

DATE:

MACHINING A WORKPIECE BY SINGLE START V-THREAD AND

KNURLING OPERATIONS USING LATHE

AIM:

To perform the single start V-Thred and knurling operations on the given work piece as per the given dimensions.

MATERIAL REQUIRED:

Mild steel rod

TOOLS REQUIRED:

Lathe Steel rule Vernier caliper Cutting tool Scriber Chuck key Tool post key Single start V-thread cutting tool Knurling tool

PROCEDURE:

1. The dimension of the given work piece are chucked by vernier caliper.2. The work piece is held in the lathe chuck properly and it is tightened by chuck key.3. The cutting tool is set in a tool post such that the point of the cutting tool coincides with the

lathe axis.4. The machine is switched on to remove the work piece at the selected speed.5. By the giving cross feed and longitudinal feed to the cutting tool the facing and turning

operations are done respectively.6. The speed of the work piece is reduced.7. The knurling operation is done by using knurling tool.8. The work piece is removed from the chuck and all the dimensions are measured and chucked.

RESULT:


EXERCISE-14

DATE:

MACHINING A WORKPIECE BY MULTI START V-THRED CUTTING OPERATION USING LATHE

AIM:

To perform the multi start V-Thread cutting operations on the given work piece as per the given dimensions.

MATERIAL REQUIRED:

Mild steel rod

TOOLS REQUIRED:

Lathe Steel rule Vernier caliper Cutting tool Scriber Chuck key Tool post key Multi start V- thread cutting tool

PROCEDURE:



operations are done respectively.6. The speed of the work piece is reduced.7. The external thread cutting operation is done using external V-thread cutting tool by engaging

thread mechanism.8. The work piece is removed from the chuck and all the dimensions are measured and chucked.

RESULT:


EXERCISE-15

DATE:

MACHINING A WORKPIECE BY BORING AND INTERNAL THREAD CUTTING OPERATIONS USING LATHE

AIM:

To perform the boring and internal thread cutting operations on the given work piece as per the given dimensions.

MATERIAL REQUIRED:

Mild steel rod

TOOLS REQUIRED:

Lathe Steel rule Vernier caliper Cutting tool Scriber Chuck key Tool post key Internal thread cutting tool

PROCEDURE:



operations are done respectively.6. The speed of the work piece is reduced.7. The external thread cutting operation is done by using external V thread cutting tool by

engaging thread cutting mechanism.8. The work piece is removed from the chuck and all the dimensions are measured and chucked.

RESULT:


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