SRI SUBRAMANYA COLLEGE OF ENGINEERING & TECHNOLOGY, PALANI.

DEPARTMENT OF MECHANICAL ENGINEERING

SEMESTER-III

MANUFACTURING TECHNOLOGY LABORATORY-I

LAB MANUAL
PREPARED BY M.PRASATH KUMAR.BE

FACULTY OF MECHANICAL ENGINEERING

EX

:1

DATE:

MAKING A GREEN SAND MOULD WITH SOLID PATTERN AIM: To Make a Green Sand Mould for the given solid Pattern. MATERIALS REQUIRED: Pattern Moulding sand Parting sand TOOLS REQUIRED: Moulding boxes Moulding board Shovel Trowel Rammers Sprue pin Riser pin Strike off bar Draw spike Vent rod

PROCEDURE: The given solid pattern is placed on the moulding board. Parting sand is applied over the pattern and the moulding board. The drag is placed on the moulding board such that the pattern is at the center of the drag box. The prepared moulding sand is filled and evenly rammed in the drag box. Exesss sand is removed using strike off bar. The drag box is turned upside down. The cope box is placed on the drag box. The sprue pin and riser pin are kept at the respective positions. The parting sand is filled and rammed in the cope box. Vent holes are made in the cope box. Sprue and riser pins are removed from the cope box. The cope box is kept aside and the pattern is removed using draw spike. The cope box is placed over the drag box.

RESULT: Thus the green sand mould cavity is prepared using the given solid pattern.

EX

:2

DATE:

MAKING A GREEN SAND MOULD WITH SPLIT PATTERN AIM: To Make a Green Sand Mould for the given split Pattern. MATERIALS REQUIRED: Pattern Moulding sand Parting sand TOOLS REQUIRED: Moulding boxes Moulding board Shovel Trowel Rammers Sprue pin Riser pin Strike off bar Draw spike Vent rod

PROCEDURE: The given split pattern is placed on the moulding board. Parting sand is applied over the pattern and the moulding board. The drag is placed on the moulding board such that the pattern is at the center of the drag box. The prepared moulding sand is filled and evenly rammed in the drag box. Excess sand is removed using strike off bar. The drag box is turned upside down. The cope box is placed on the drag box. The sprue pin and riser pin are kept at the respective positions. The parting sand is filled and rammed in the cope box. Vent holes are made in the cope box. Sprue and riser pins are removed from the cope box. The cope box is kept aside and the pattern is removed using draw spike. The cope box is placed over the drag box.

RESULT: Thus the green sand mould cavity is prepared using the given solid pattern.

EX: 3 HORIZONTAL WELDING AIM:

DATE:

To weld the two metal pieces of mild steel to form a horizontal welding (Single V butt joint) using arc welding machine. MATERIALS REQUIRED: Mild steel plate- (100x50x6)mm -2 Nos TOOLS REQUIRED: Welding transformer Electrode Gloves Tong Chipping hammer Wire brush Welding shield Electrode holder

PROCEDURE: First study and measure the given work for the required dimensions. The two mild steel plates to be welded are cleaned using the wire brush. Then the plate being welded is kept on a steel plate which will act as a cathode. The welding electrode is held in the holder manually. The welding transformer is switched on and set the required value of current density. The plates are maintained with a gap of 3mm and do the tack welds at the two ends of the plates. The tack weld kept the work piece in a same position without any movements. After that the welding electrode is bring to make a contact with one end work piece and the welding is carried out by fulfilling the gap between the two plates. Then the work is allowed to air cooling or water cooling. Finally the slag which is formed on the work is removed using chipping hammer. RESULT:

Thus the horizontal welding of two steel plates is carried out using Arc welding.

EX: 4 VERTICAL WELDING AIM:

DATE:

To weld the metal pieces of mild steel to form a vertical welding using arc welding machine. MATERIALS REQUIRED: Mild steel-(100x50x6)mm -2 Nos TOOLS REQUIRED: Welding transformer Electrode Gloves Tong Chipping hammer Wire brush Welding shield Electrode holder

PROCEDURE: First study and measure the given work for the required dimensions. The two mild steel plates to be welded are cleaned using the wire brush. Then the plate being welded is kept on a steel plate which will act as a cathode. The welding electrode is held in the holder manually. The welding transformer is switched on and set the required value of current density. The plates are maintained with a gap of 3mm and do the tack welds at the two ends of the plates. The tack weld kept the work piece in a same position without any movements. After that the welding electrode is bring to make a contact with one end work piece and the welding is carried out by fulfilling the gap between the two plates. Then the work is allowed to air cooling or water cooling. Finally the slag which is formed on the work is removed using chipping hammer. RESULT: Thus the vertical welding of two steel plates is carried out using Arc welding.

EX: 5 OVER HEAD WELDING AIM:

DATE:

To weld the metal pieces of mild steel to form a overhead welding using arc welding machine. MATERIALS REQUIRED: Mild steel-(100x50x6)mm -2 Nos TOOLS REQUIRED: Welding transformer Electrode Gloves Tong Chipping hammer Wire brush Welding shield Electrode holder

PROCEDURE: First study and measure the given work for the required dimensions. The two mild steel plates to be welded are cleaned using the wire brush. Then the plate being welded is kept on a steel plate which will act as a cathode. The welding electrode is held in the holder manually. The welding transformer is switched on and set the required value of current density. The plates are maintained with a gap of 3mm and do the tack welds at the two ends of the plates. The tack weld kept the work piece in a same position without any movements.(The Planes should be at 90 to each other) After that the welding electrode is bring to make a contact with one end work piece and the welding is carried out by fulfilling the gap between the two plates. Then the work is allowed to air cooling or water cooling. Finally the slag which is formed on the work is removed using chipping hammer. RESULT: Thus the overhead welding of two steel plates is carried out using Arc welding.

SQUARE TRAY

SIZE- 100 X 100 mm

EX: 6

DATE:

MAKING OF SQUARE TRAY AIM: To make a square tray using the given sheet metal. MATERIALS REQUIRED: 22 Gauge Galvanized iron (GI) sheet. TOOLS REQUIRED: Steel rule Mallet Scriber Divider Protractor Snips Stakes Rivet set Ball peen hammer

PROCEDURE: The size of the given sheet is checked for its dimensions using a steel rule. Then the sheet is leveled on the leveling plate. The development procedure is followed the same as the square. The dimensions are marked as shown in figure. The sheet is cut as per the marked dimensions by straight snips. Then a single hamming is made on the four sides of the tray as shown in figure. The four sides of the tray are bent to 90 using the stakes anvil. Finally all the corners of the tray are joined by riveting. RESULT: Thus desired square tray is made using the given sheet metal.

RECTANGULAR TRAY

SIZE- 120 X 100 mm

EX: 7 MAKING OF RECTANGULAR TRAY AIM: To make a rectangular tray using the given sheet metal. MATERIALS REQUIRED: 22 Gauge Galvanized iron (GI) sheet. TOOLS REQUIRED: Steel rule Mallet Scriber Divider Protractor Snips Stakes Rivet set Ball peen hammer

DATE:

PROCEDURE: The size of the given sheet is checked for its dimensions using a steel rule. Then the sheet is leveled on the leveling plate. The development procedure is followed the same as the square. The dimensions are marked as shown in figure. The sheet is cut as per the marked dimensions by straight snips. Then a single hamming is made on the four sides of the tray as shown in figure. The four sides of the tray are bent to 90 using the stakes anvil. Finally all the corners of the tray are joined by riveting. RESULT: Thus desired rectangular tray is made using the given sheet metal.

STEP TURNING

EX: 8 STEP TURNING OPERATION AIM:

DATE:

To machine a work piece by step turning operation using a Lathe. MATERIALS REQUIRED: MS round rod-103x32 mm. TOOLS REQUIRED: Lathe machine Tool holder with key Cutting tool Outside Caliper Steel rule Vernier Caliper

PROCEDURE: The given work piece is held firmly in a lathe chuck. The given work piece is set in a tool post such that the point of the cutting tool coincides with the lathe axis. The machine is switched on to revolve the work piece at the selected speed. By giving cross feed and longitudinal feed to the cutting tool, the facing and turning operations are done respectively. Then the step turning operation is carried out and work piece until the required dimensions are obtained. Finally switched off the machine and then removed the work piece from the chuck. RESULT: Thus the step turning operation are performed on the lathe to obtain the required dimensions are machined.

TAPER TURNING

EX: 9

DATE:

TAPER TURNING OPERATION USING COMPOUND REST METHOD AIM: To machine a work piece by taper turning operation by compound rest method using a Lathe. .MATERIALS REQUIRED: MS round rod-103x32 mm. TOOLS REQUIRED: Lathe machine Tool holder with key Cutting tool FORMULA USED: Taper angle () = (D-d)/2l Where D =Large diameter of taper in mm d =Small diameter of taper in mm l =Length of tapered part in mm =Angle of taper PROCEDURE: The given work piece is held firmly in a lathe chuck. The given work piece is set in a tool post such that the point of the cutting tool coincides with the lathe axis. The machine is switched on to revolve the work piece at the selected speed. By giving cross feed and longitudinal feed to the cutting tool, the facing and turning operations are done respectively. The compound rest is swiveled for the calculated taper angle. By giving angular feed to the cutting tool through the compound slide, taper turning operation is done. Finally switched off the machine and then removed the work piece from the chuck. RESULT: Thus the step turning operation are performed on the lathe to obtain the required dimensions are machined. Outside Caliper Steel rule Vernier Caliper

DRILLING AND KNURLING

EX: 10 DRILLING AND KNURLING OPERATION AIM:

DATE:

To machine a work piece by drilling & knurling operations using a Lathe. .MATERIALS REQUIRED: MS round rod-50x30 mm. TOOLS REQUIRED: Lathe machine Drill bit Knurling tool PROCEDURE: The given work piece is held firmly in a lathe chuck. The given work piece is set in a tool post such that the point of the cutting tool coincides with the lathe axis. The machine is switched on to revolve the work piece at the selected speed. By giving cross feed and longitudinal feed to the cutting tool, the facing and turning operations are done respectively. By giving longitudinal feed to the tail stock, the drilling operation is done. The speed of the work piece is reduced and the knurling operation is done using knurling tool. Finally switched off the machine and then removed the work piece from the chuck. RESULT: Thus the drilling and knurling operation are performed on the lathe to obtain the required dimensions are machined. Outside Caliper Steel rule Vernier Caliper