1

MANUFACTURING TECHNOLOGY LAB I

MANUAL


ME-2207

















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CONTENTS
S.NO DATE EXPERIMENT MARKS SIGNATURE OF
THE STAFF





















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Ex. No: 1
Date:

STUDY OF BASIC MACHINING LATHE
SAFETY PRECAUTIONS FOR MACHINING WORK
Job should be tightly held in the chuck.
If the job is held in between the centres, then apply grease on the nose of dead centre,
otherwise it will burnt out due to excess heat.
Do not measure the job while the work piece is rotating.
Do not leave the chuck key in the chuck.
Do not try to stop the lathe chuck or job with hands.
Do not handle metal chips by hand.
Do not give more depth of cut while the job is rotating at high speed.
Tighten the tool in the tool post.
Do not stand close to the rotating work piece and do not bring your face close it.
Do not reduce or increase the speed when the lathe operation is going on.

PRINCIPLE OF LATHE
In lathe the work piece is held in the chuck, a work holding device. The cutting tool is
mounted in the tool post. The chuck is rotated by means of electric power. When the chuck
rotates the work piece also rotates. The tool is moved against the rotating work piece by giving
small amount of depth of cut. Here the material is removed in form of chips.
Lathe machine has the following parts as shown in figure:
Bed
Head stock
Carriage
Saddle
Cross slide
Compound rest
Tool post
Apron
Lead screw
Tailstock


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BED
It is the base of the machine on its left side the head stock is mounted. A movable
casing called tail stock is mounted on the right side.
HEAD STOCK
It consists of a spindle, gears and speed change levers. It is used to transmit the
motion of the job.
CARRIAGE
Carriage is used to carry a tool to bring it in contact with the rotating work piece or to
with draw from such a contact.
SADDLE
It is H shaped part fitted on the lathe bed. There is a hand wheel to move it on the
bed way. Cross slide, compound rest and tool post are fitted on this saddle.
CROSS SLIDE
It is on the upper side of saddle in the form of dove tail. A band wheel is provided to
drive the cross slide.
COMPOUND REST
It is fitted over the cross slide on a turn table. It permits both parallel and angular
movements to the cutting tool.
TOOL POST
It is fitted on the top most part of compound rest. Tool is mounted on this tool post.
Cutting tool is fixed in it with the help of screw.
APRON
It is the hanging part in front of the carriage. It accommodates the mechanism of hand
and power feed to the cutting tool for carrying out different operations.
HEAD SCREW
It is a long screw with ACME threads. It is used for transmitting power for
automatic feed or feed for thread cutting operating.
TAIL STOCK

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It is located at the right end of the lathe bed and it can be positioned anywhere in the
bed. It is used for supporting lengthy jobs and also carries tool to carry out operations
such as tapping, drilling and reaming.

LATHE OPERATIONS
Simple Turning
It is operation for reducing the diameter of the work piece. The turning tool is used for
this operation. More feed of tool is given for rough turning. Then, less feed is given for finishing.
In this operation, work is held in chuck and tool is set to the centre height of the work
piece.
Taper Turning
Taper is defined as the uniform change in the diameter of a work piece measured along
its length.
Calculation for taper turning
Taper = (D d) / 2L
Where,
D = larger diameter
d = smaller diameter
L = length of taper
Taper turning operation shown in figure.
This can be done by the following methods:
1. Compound rest method
2. Tail stock set over method
3. Using form tool
4. Taper attachment method.
Drilling
Drilling is the operation of making a hole on the work piece. Here the job is held in the
tail stock sleeve. Feed is given by rotating the hand wheel in the tail stocks which pushes the
tailstock sleeve
Facing

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It is done for getting fine finish on the face of the job. Facing tool is set at an angle to the
work piece. In this operation the tool is fed from the centre of work piece towards the outer
surface against the rotating work piece. Depth of cut is low for the facing operation.


Step turning
It is similar to the process of turning but in this case different diameter in step of various
sizes are taken on the work piece roughing tool i.e. used for rough turning and the knife tool is
used for finishing cut.
Boring
It is the process of enlarging a
drilled hole. A special type of boring
tool is used for this purpose.










Mark Allocation
Performance 05
Observation 05
Attendance 05
Viva 05
Total 20

7

Ex. No: 2
Date:

FACING, PLAIN TURNING AND STEP TURNING
AIM:
To obtain the required shape and size of the given work piece by facing, plain turning and
step turning.
MATERIAL SUPPLIED:
Mild Steel round rod of size ____________________mm
TOOLS REQUIRED:
Single point cutting tool
Vernier calliper
Steel rule
Outside calliper
Marking gauge
SEQUENCE OF OPERATIONS:
Facing
Turning
Step turning

PROCEDURE:
1. The given work piece is checked for its dimensions by using measuring devices.
2. Loosen the jaws in the chuck using the chuck key to position the work piece, and
then tighter the jaws
3. Check the center of the job using marking gauge. If the center of the job is not in
the lathe axis readjust the chuck and fix the job in the lathe axis
4. Fix the single point cutting tool in the tool post

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5. Select the corresponding spindle speed and feed the before starting the operation
6. Switch ON the lathe and do the facing operation on the one side of the job
7. Move the carriage near the work piece. Give it small cross feed and then move the
carriage
8. Then stop the machine, release the chuck, mark the length, invert the job and
refax in the chuck
9. Do the facing operation on the other side of the job.
10. Then the plain turning is done to reduce the diameter of the work piece
11. Finally, the dimensions of work piece are again checked





RESULT:
Thus the required size and shape of the given work piece is detained












Mark Allocation
Performance 05
Observation 05
Attendance 05
Viva 05
Total 20

9

Ex. No: 3
Date: TAPER TURNING, THREAD CUTTING AND KNURLING
AIM:
To perform taper turning, thread cutting and knurling operation on a given cylindrical work piece.

MATERIAL SUPPLIED:
Mild Steel round rod of size ____________________mm

TOOLS REQUIRED:
Single point cutting tool
Vernier calliper
Steel rule
Outside calliper
Marking gauge
Thread cutting tool
Thread pitch gauge
Knurling tool
SEQUENCE OF OPERATIONS:
Taper turning
Thread cutting
Knurling
CALCULATION:



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Taper turning:
The angle is determined by using the formula,
Tana= (D-d)/2L
Where D=Larger diameter of the work piece
d=smaller dia of the work piece
L=taper length of the work piece
Thread Cutting:
(Driver teeth)/ (Driven teeth) = (Pitch of the work)/ (Pitch of the lead screw)

PROCEDURE:
1. The given work piece is checked for its dimensions by using measuring devices.
2. Loosen the jaws in the chuck using the chuck key to position the work piece.
3. Check the center of the job using marking gauge.
4. Fix the single point cutting tool in the tool post.
5. Select the corresponding spindle speed and feed the before starting the operation
6. Work the taper length on the job
7. Calculate the taper angle and then the compound rest is received to the required angle
8. Cutting tool is moved at an angle to the lathe axis
9. The gear ratio of no of teeth required on change gear are calculated

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10. The current size of gears in the change gear train is fixed
11. Rotation of spindle should be sent out fourth of speed
12. The cutting tool height is set which is equal to the centre of work piece
13. The cross slide hand wheel is rotated tilled tool touches the work piece
14. The half nut is engaged when any one making on the dial coincides with reference mark on
chasing dial
15. Now the tool will move in helical path on the work piece to form thread
16. Fix the knurling tool in the tool post
17. Then the tool is held in tool post and passed again checked





RESULT:
Thus the taper turning thread cutting and knurling operation of required dimensions was
determined

Mark Allocation
Performance 05
Observation 05
Attendance 05
Viva 05
Total 20

12

Ex. No: 4 BOARING AND INTERNAL THREAD CUTTING
Date:
AIM:
To perform Boaring and internal thread cutting operation on a given cylindrical work piece
MATERIAL SUPPLIED:
Mild Steel round rod of size ____________________mm

TOOLS REQUIRED:
Single point cutting tool
Vernier calliper
Steel rule
Outside calliper
Marking gauge
Thread cutting tool
Thread pitch gauge
Boaring tool
SEQUENCE OF OPERATIONS:
Boaring
Internal Thread cutting
CALCULATION:




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Thread Cutting:
(Driver teeth)/ (Driven teeth) = (Pitch of the work)/(Pitch of the lead screw)
PROCEDURE:
1. The given work piece is checked for its dimensions by using measuring devices.
2. Loosen the jaws in the chuck using the chuck key to position the work piece.
3. Check the center of the job using marking gauge.
4. Fix the single point cutting tool in the tool post.
5. Select the corresponding spindle speed and feed the before starting the operation
6. The drill is fitted in the tail stock spindle
7. The tail stock is moved over the bed and chambered near the work piece
8. When the job rotates, the drill bit is fed into work by turning tail stock hand wheel upto required path
9. Then Boaring tool is fitted on the tool post and fed parallel to the axis of lathe
10. Boar the work piece to required dia
11. The gear ratio and no teeth required on change gears are calculated
12. The current size of gears in the change gear train is fixed
13. The rotation of the spindle should be sent one fourth of the speed required for turning
14. The cross slide hand wheel is rotated till the tool touches the work piece
15. Now the tool will move in helical path on work piece to form thread
16. After one pass the half nut is dischanged and the tool is withdrawn simultaneously

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17. The tool is adjusted to the required depth of cut and rearranged the half nut for repeating the same
procedure till the required depth is obtained
18. Finally, the dimensions of work piece are again checked





RESULT:
Thus the Boaring and internal thread cutting operation of required dimension was
determined

Mark Allocation
Performance 05
Observation 05
Attendance 05
Viva 05
Total 20

15


Ex.No: 5
Date:
STUDY OF WELDING
SAFETY PRECAUTIONS FOR ARC WELDING
Check the ground connection and insulation of all the wires.
They are should be observed only through a shield or goggles.
Always wear the safety hand gloves, apron and leather shoes.
Use proper capacity current cables.
Switch off the welding machines when leaving from the work.
Remove the slag by chipping hammer only.
To relieve strain or irritation on the eyes, eye drops may be applied.
SAFETY PRECAUTIONS FOR GAS WELDING
As far as possible use a spark lighter for igniting the flame.
Oil, petrol, gaseous and other explosive materials should be kept away from the
welding location.
Goggles face shields and gloves must be used while welding.
Dont keep the blow pipe on a wooden blank during the course of welding.
Oil and petrol tanks and tanks with inflammable materials should be perfectly
emptied and cleaned before welding them.
Secure cylinder- in-use against falling, which may knock off the valve.
Any repairable parts of the welding equipment should be sent to the manufacturer for
necessary repairs.


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INTRODUCTION
Arc welding is one of several fusion processes for joining metals. By applying intense heat, metal at
the joint between two parts is melted and caused to intermix-directly, or more commonly, with an
intermediate molten filler metal. Upon cooling and solidification, a metallurgical bond is created. In arc
welding, the intense heat needed to melt metal is produced by an electric arc. When the circuit is
energized, the flow of electric current through the electrode heats the electrode by virtue of its electric
resistance. When the electrode tip is touched to the work piece and then withdrawn to leave a gap
between the electrode and work piece, the arc jumping the short gap presents a further path of high
electric resistance, resulting in the generation of an extremely high temperature in the region of the
sustained arc. The temperature reaches about 6000
o
C, which is more than adequate to melt. This heat
melts both the base metal and the electrode, producing a pool of molten metal sometimes called a
crater.

WELDING TOOLS
Chipping hammer
Electrode holder
Wire brush
Helmet
Goggle
Leather gloves
Hand screen
Tongs




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1. CHIPPING HAMMER
A chipping hammer is chisel shaped one and it is used to remove the slag from the weld bead.


2. ELECTRODE HOLDER
It is device used for mechanically holding the electrode and conducting current to it. Jaws are made
to hold the bare end of the electrode in either vertical or an angular position. These are fully insulated
and the jaws are made of metals having high heat conductivity.
3. WIRE BRUSH
A wire brush made up of shift steel wire, embedded in wood, removes small particles of slag from
the weld bead after the chipping hammer is used.

4. HELMET
It is used shield provide better protection to face and neck of the welder. It is fitted with suitable
fitter lens.
5. GOGGLE
This is protective clothing for the eyes. It is worn to avoid radiation, spatter and hot slag.
6. LEATHER GLOVES
This is a flame-retardant outfits worn by a welder to protect the under clothing and the body from the
sparks, the metal and the hot metal being welded.
7. HAND SCREEN
It is a protective device used in arc welding. A hand shield is held in the hand of the welder and it is
fitted with a suitable fitter lens.
8. TONGS
Tongs are used to handle the hot metal- welding job while cleaning; they are also used to hold the
metal for hammering.
TYPES OF WELD JOINTS
There are two major classes of weld fillet and butt.
Fillet welds. These welds are roughly triangular in cross section and between two
surfaces not in the same plane and the weld metal are substantially placed alongside the
components being joined.

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Butt welds. A butt weld is made between two pieces of metal usually in the same
plane, the weld metal maintaining continuity between the sections. The most common
welds are given below.
Lap joint
Butt joint
T-joint and the
Edge joint

THE WELDING CURRENT
Both direct and alternating currents may be used for arc welding. However, most work on mild steel
is done using AC. AC welding machines have several advantages over DC machines, among them being
a lower purchase cost, higher operating efficiency and negligible maintenance. The quality of welds
produced using AC is equally as good as when DC is used. However, AC is limited in that it will not
satisfactorily run many of the non-ferrous types of electrodes.
GAS WELDING
Welding is a way of joining metals by means of heat liberated by burning the gas like oxyacetylene
and acetylene. The oxygen and acetylene is obtained under high pressure in cylinders which are fitted
with pressure regulators.
Each cylinder is connected to the blowpipe by flexible hoses. The oxygen cylinders are painted black
and acetylene cylinders are painted maroon. When acetylene is mixed with oxygen in correct
proportions in the welding torch, ignition is taking place. The flame resulting at the tip of the torch is
sufficiently hot to melt and join the parent metal. The flame temperature is about 3200
o
C. The filler
metal rod is generally added to the molten metal pool to build up the seam for greater strength.
TYPES OF FLAMES
Neutral Flame (Oxygen, Acetylene in equal proportions)
Oxidizing Flame(excess of Oxygen)
Reducing Flame(excess of Acetylene)

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NEUTRAL FLAME
A neutral flame is produced when approximately equal volumes of oxygen and acetylene are mixed
in the welding torch and burnt at the torch tip. The temperature of the neutral flame is of the order of
about 3260
o
C. The flame has inner cone which is light blue in colour.

OXIDIZING FLAME
If the volume of the oxygen supplied to the neutral flame is increased, then resulting flame will be
oxidizing flame (i.e., rich in oxygen). The temperature of oxidizing flame is of the order of about
3482
o
C. Normally the outr flame envelope is much shorter. It has very small white inner cone.
REDUCING FLAME
If the volume of the oxygen supplied to the neutral flame is reduced, the resulting flame will be a
carburizing or reduced flame (i.e., rich in acetylene). In this case, flame is recognized by acetylene
feather which exists between the inner cone and outer envelope. The outer flame envelope is longer than
that of the neutral flame and is usually much brighter in color. It has appropriate temperature of 3038
o
C.

APPLICATIONS OF WELDING
Today, almost all the commonly employed metals and their alloys can be welded by
the arc welding process.
Shielded metal arc welding is used both as a fabrication process and for maintenance
and repair jobs.
The process finds application in
Air receiver, tank, boiler, structural and pressure vessel fabrications.
Ship building.
Arc welding is used in building and bridge
construction.


Mark Allocation
Performance 05
Observation 05
Attendance 05
Viva 05
Total 20

20

Ex. No: 6
Date: SQUARE BUTT JOINT
AIM:
To join two given metal plates by a square butt joint in arc welding.
MATERIAL SUPPLIED:
Mild Steel Plate of size
TOOLS REQUIRED:
Welding transformer
Welding rods
Safety gloves
Goggle
Tong
Chipping hammer
Flat file
Try square, etc.,
SEQUENCE OF OPERATIONS:
Edge preparation (Removal of rust, scale etc.,)
Tacking
Welding
Cooling
Chipping
Cleaning



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PROCEDURE:
1. The surface to be welded is cleaned and the edges of the plates may be filed for perfect joint
and more strength.
2. The welding rod is held in the electrode holder and the ground clamp is clamped to the plate
to be welded.
3. The plates to be welded are positioned touching each other (butting) and tag weld is done on
the ends to avoid the movement of the plates during welding.
4. Now start welding from one end of the plates.
5. The electric arc produced melts the welding rod and joints the two metal plates. Maintain a
gap of 3 mm between the plate and the welding rod.
6. The welding process is completed by removing slag using chipping hammer.







RESULT:
Thus the two metal plates were joined by square butt weld.

Mark Allocation
Performance 05
Observation 05
Attendance 05
Viva 05
Total 20

22

Ex. No: 7
Date:
LAP JOINT
AIM:
To join two given metal plates by a Lap joint in arc welding.
MATERIAL SUPPLIED:
Mild Steel Plate of size
TOOLS REQUIRED:
Welding transformer
Welding rods
Safety gloves
Goggle
Tong
Chipping hammer
Flat file
Try square, etc.,
SEQUENCE OF OPERATIONS:
Edge preparation (Removal of rust, scale etc.,)
Tacking
Welding
Cooling
Chipping
Cleaning


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PROCEDURE:
1. The surface to be welded is cleaned and the edges of the plates may be filed for perfect joint
and more strength.
2. The welding rod is held in the electrode holder and the ground clamp is clamped to the plate
to be welded.
3. The plates to be welded are positioned touching each other (butting) and tag weld is done on
the ends to avoid the movement of the plates during welding.
4. Now start welding from one end of the plates.
5. The electric arc produced melts the welding rod and joints the two metal plates. Maintain a
gap of 3 mm between the plate and the welding rod.
6. The welding process is completed by removing slag using chipping hammer.







RESULT:
Thus the two metal plates were joined by Lap weld.


Mark Allocation
Performance 05
Observation 05
Attendance 05
Viva 05
Total 20

24


Ex. No: 8
Date:
TEE FILLET JOINT
AIM:
To join two given metal plates by a Tee Fillet joint in arc welding.
MATERIAL SUPPLIED:
Mild Steel Plate of size
TOOLS REQUIRED:
Welding transformer
Welding rods
Safety gloves
Goggle
Tong
Chipping hammer
Flat file
Try square, etc.,
SEQUENCE OF OPERATIONS:
Edge preparation (Removal of rust, scale etc.,)
Tacking
Welding
Cooling
Chipping
Cleaning

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PROCEDURE:
1. The surface to be welded is cleaned and the edges of the plates may be filed for perfect joint
and more strength.
2. The welding rod is held in the electrode holder and the ground clamp is clamped to the plate
to be welded.
3. The plates to be welded are positioned touching each other (butting) and tag weld is done on
the ends to avoid the movement of the plates during welding.
4. Now start welding from one end of the plates.
5. The electric arc produced melts the welding rod and joints the two metal plates. Maintain a
gap of 3 mm between the plate and the welding rod.
6. The welding process is completed by removing slag using chipping hammer.







RESULT:
Thus the two metal plates were joined by Tee Fillet weld.












Mark Allocation
Performance 05
Observation 05
Attendance 05
Viva 05
Total 20

26

Ex. No: 9
Date:
STUDY OF SHEET METAL
SAFETY PRECAUTIONS OF SHEET METAL
Heavy sheet must be handled by using gloves.
Check whether head portion of the mallet and hammer should be tightly fixed to the handle.
Respective snips should be selected according to the sheet metal thickness.
Burrs should be removed in the edges of the sheet metal after the cutting process.
Do not let sheet metal slip through your hands.
While cutting operation, blade should be perpendicular to the job and along the marking line.
Adequate care should be taken while folding, hamming or scaming operations.
Waste materials should be cleaned by using wire brush.
Necessary sheet metal working tools should be collectively selected and handled because that
avoids confusion.
High force should not be applied while leveling the plate.

GENERAL PROCEDURE FOR SHEET METAL WORK

The exact size and shape of the sheet to be cut is given by the development of the concerned
object.
The development is drawn on a flat sheet metal and then the sheet is cut.
The cut sheet is folded or rolled to the required shape before the joints are made by welding
or any other form of fastening.

SPECIFICATION OF SHEET METAL
The sheets are specified by standard gauge numbers. Each gauge designates a definite
thickness. The gauge number can be identified by standard wire gauge (or) S.W.G.
The following table shows gauge numbers and their corresponding thicknesses of sheet.
The larger the gauge numbers, the lesser the thickness and vice versa.


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S.W.G. 10 12 14 16 18 20 22 25 26 30
Thickness 3.2 2.6 2.0 1.6 1.2 0.9 0.7 0.6 0.4 0.3

TOOLS USED IN SHEET METAL WORK
SNIPS (OR) SHEARS
Snips are hand sheets, varying in length from 200mm to 600mm. 200mm and 250mm
lengths are most commonly used.
Curved snips or bend snips are used for trimming along inside curves.
STRIKING TOOLS
HAMMERS
Hammers are used in sheet metal work for following: stretching, leveling,
riveting, strengthening of sheet metal joints, etc.
PUNCHES
In sheet metal work, punch is used foe making out work, locating centers etc. there
are two types of punches.
SUPPORTING TOOLS
STAKES
Stakes are nothing but anvils of sheet metal workers, used for bending, hamming,
scaming, forming, etc. using hammers or mallet.
BENDING TOOLS
Flat nose pliers and round nose pliers are used in sheet metal work for forming and
holding work.

LAYOUT TOOLS
SCRIBER
It is a long wire of steel with its one end sharply pointed and hardened, to scratch a
line on the sheet metal for laying out patterns.

DIVIDERS
Dividers are used for drawing circles or arcs on sheet metal. They are used to mark a
desired distance between two points and to divide lines into equal parts.

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TRAMMELS
It is used for making of arcs and circles. Maximum size of the arc that can be
described depends on the length of the beam in scriber.
GROOVER
GROOVING
In order to join the sheet metal jobs, their ends are grooved with the help of grooving
tools. This process is called grooving.
SHEET METAL OPERATIONS
shearing
bending
SHEARING
The following are the basic shearing operations.
Cutting off
Parting
Blanking
Punching
Notching
Slitting
Lancing
Nabbing
Trimming

BENDING
It means that the metal is stressed beyond the elastic limit, so that the metal is bent into
right angle and forming occurs when complete items or parts are shaped. It incorporates angle
bending, roll forming and scaming.








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Ex. No: 10
Date:
MODEL MAKING SQUARE TRAY
AIM:
To make a square tray from a given metal sheet.

TOOLS REQUIRED:
Mallet
Snip
Stake
Steel Rule
Ball peen hammer
Straight edge
Rivets
Scriber, etc.,
PROCEDURE:
1. The given metal sheet is smoothed using mallet.
2. The development of square tray is drawn on the sheet with given dimensions using the
scriber.
3. The unmarked and excess portions in the sheet are removed using snip.
4. Folding is done as per the given order using mallet and stake.
5. Bending is done as per the given dimension using the stake and mallet.
6. The tray is riveting using the given rivets and hammer.


30



























RESULT:
Thus the square tray with required dimensions is obtained.





Mark Allocation
Performance 05
Observation 05
Attendance 05
Viva 05
Total 20

31

Ex. No: 11
Date:
MODEL MAKING RECTANGULAR TRAY
AIM:
To make a rectangular tray from a given metal sheet.

TOOLS REQUIRED:
Mallet
Snip
Stake
Steel Rule
Ball peen hammer
Straight edge
Rivets
Scriber, etc.,
PROCEDURE:
1. The given metal sheet is smoothed using mallet.
2. The development of the rectangular tray is drawn on the sheet with given dimensions using
the scriber.
3. The unmarked and excess portions in the sheet are removed using snip.
4. Folding is done as per the given order using mallet and stake.
5. Bending is done as per the given dimension using the stake and mallet.
6. The tray is riveting using the given rivets and hammer.


32






























RESULT:
Thus the rectangular tray with required dimensions is obtained.
Mark Allocation
Performance 05
Observation 05
Attendance 05
Viva 05
Total 20

33


Ex. No: 12
Date:
MODEL MAKING FRUSTUM OF A CONE FUNNEL
AIM:
To make a funnel from a given metal sheet.

TOOLS REQUIRED:
Mallet
Snip
Stake
Steel Rule
Ball peen hammer
Straight edge
Rivets
Scriber, etc.,
PROCEDURE:
The given metal sheet is smoothed using mallet.
The development of the funnel is drawn on the sheet with given dimensions using the
scriber.
The unmarked and excess portions in the sheet are removed using snip.
Folding is done as per the given order using mallet and stake.
Bending is done as per the given dimension using the stake and mallet.
The tray is riveting using the given rivets and hammer.

34





























RESULT:
Thus the funnel with required dimensions is obtained.

Mark Allocation
Performance 05
Observation 05
Attendance 05
Viva 05
Total 20

35


Ex. No: 13
Date:

STUDY OF FOUNDRY


A foundry is a factory that produces metal castings. Metals are cast into shapes by
melting them into a liquid, pouring the metal in a mould, and removing the mould material or
casting after the metal has solidified as it cools. The most common metals processed are
aluminium and cast iron. However, other metals, such as bronze, steel, magnesium, copper, tin,
and zinc, are also used to produce castings in foundries.
Process:
In metalworking, casting involves pouring liquid metal into a mold, which contains a
hollow cavity of the desired shape, and then allowing it to cool and solidify. The solidified part is
also known as a casting, which is ejected or broken out of the mold to complete the process.
Casting is most often used for making complex shapes that would be difficult or uneconomical to
make by other methods.
Melting:
Melting is performed in a furnace. Virgin material, external scrap, internal scrap, and
alloying elements are used to charge the furnace. Virgin material refers to commercially pure
forms of the primary metal used to form a particular alloy. Alloying elements are either pure
forms of an alloying element, like electrolytic nickel, or alloys of limited composition, such as
ferroalloys or master alloys. External scrap is material from other forming processes such as
punching, forging, or machining. Internal scrap consists of gates, risers, defective castings, and
other extraneous metal oddments produced within the facility.
The process includes melting the charge, refining the melt, adjusting the melt chemistry
and tapping into a transport vessel. Refining is done to remove deleterious gases and elements
from the molten metal to avoid casting defects. Material is added during the melting process to
bring the final chemistry within a specific range specified by industry and/or internal standards.
Certain fluxes may be used to separate the metal from slag and/or dross and degassers are used to
remove dissolved gas from metals that readily dissolve certain gasses. During the tap, final
chemistry adjustments are made.




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Furnace:
Several specialized furnaces are used to melt the metal. Furnaces are refractory lined
vessels that contain the material to be melted and provide the energy to melt it. Modern furnace
types include electric arc furnaces (EAF), induction furnaces, cupolas, reverberatory, and
crucible furnaces. Furnace choice is dependent on the alloy system and quantities produced. For
ferrous materials, EAFs, cupolas, and induction furnaces are commonly used. Reverberatory and
crucible furnaces are common for producing aluminium, bronze, and brass castings.
Furnace design is a complex process, and the design can be optimized based on multiple
factors. Furnaces in foundries can be any size, ranging from small ones used to melt precious
metals to furnaces weighing several tons, designed to melt hundreds of pounds of scrap at one
time. They are designed according to the type of metals that are to be melted. Furnaces must also
be designed based on the fuel being used to produce the desired temperature. For low
temperature melting point alloys, such as zinc or tin, melting furnaces may reach around 500 C.
Electricity, propane, or natural gas are usually used to achieve these temperatures. For high
melting point alloys such as steel or nickel based alloys, the furnace must be designed for
temperatures over 1600 C. The fuel used to reach these high temperatures can be electricity (as
employed in electric arc furnaces) or coke.
The majorities of foundries specializes in a particular metal and have furnaces dedicated
to these metals. For example, an iron foundry (fore cast iron) may use a cupola, induction
furnace, or EAF, while a steel foundry will use an EAF or induction furnace. Bronze or brass
foundries use crucible furnaces or induction furnaces. Most aluminium foundries use either
electric resistance or gas heated crucible furnaces or reverberatory furnaces.
Degassing:
In the case of aluminium alloys, a degassing step is usually necessary to reduce the
amount of hydrogen dissolved in the liquid metal. If the hydrogen concentration in the melt is
too high, the resulting casting will be porous as the hydrogen comes out of solution as the
aluminium cools and solidifies. Porosity often seriously deteriorates the mechanical properties of
the metal.
An efficient way of removing hydrogen from the melt is to bubble argon or nitrogen
through the melt. To do that, several different types of equipment are used by foundries. When
the bubbles go up in the melt, they catch the dissolved hydrogen and bring it to the top surface.
There are various types of equipment which measure the amount of hydrogen present in it.
Alternatively, the density of the aluminium sample is calculated to check amount of hydrogen
dissolved in it.


37

Mould making:
In the casting process a pattern is made in the shape of the desired part. This pattern is
made out of wax, wood, plastic, or metal. Simple designs can be made in a single piece or solid
pattern. More complex designs are made in two parts, called split patterns. A split pattern has a
top or upper section, called a cope, and a bottom or lower section called a drag. Both solid and
split patterns can have cores inserted to complete the final part shape. Cores are used to create
hollow areas in the mould that would otherwise be impossible to achieve. Where the cope and
drag separates is called the parting line.
When making a pattern it is best to taper the edges so that the pattern can be removed
without breaking the mould. This is called draft. The opposite of draft is an undercut where there
is part of the pattern under the sand making it impossible to remove the pattern without
damaging the mould. The moulds are constructed by several different processes dependent upon
the type of foundry, metal to be poured, quantity of parts to be produced, size of the casting and
complexity of the casting. These mould processes include:
Sand casting Green or resin bonded sand mould.
Lost-foam casting Polystyrene pattern with a mixture of ceramic and sand mould.
Investment casting Wax or similar sacrificial pattern with a ceramic mould.
Ceramic mould casting Plaster mould.
V-process casting Vacuum is used in conjunction with thermoformed plastic to form sand
moulds. No moisture, clay, or resin is needed for sand to retain shape.
Die casting metal mould.
Billet (ingot) casting Simple mould for producing ingots of metal normally for use in other
foundries.
Pouring:
Bronze poured from a ladle into a mould, using the ancient lost-wax casting process
In a foundry, molten metal is poured into moulds. Pouring can be accomplished with
gravity, or it may be assisted with a vacuum or pressurized gas. Many modern foundries use
robots or automatic pouring machines for pouring molten metal. Traditionally, moulds were
poured by hand using ladles.



38

Shakeout:
The solidified metal component is then removed from its mould. Where the mould is
sand based, this can be done by shaking or tumbling. This frees the casting from the sand, which
is still attached to the metal runners and gates - which are the channels through which the molten
metal travelled to reach the component itself.
Degating:
Degating is the removal of the heads, runners, gates, and risers from the casting. Runners,
gates, and risers may be removed using cutting torches, band saws or ceramic cut off blades. For
some metal types, and with some gating system designs, the sprue, runners, and gates can be
removed by breaking them away from the casting with a sledge hammer or specially designed
knockout machinery. Risers must usually be removed using a cutting method (see above) but
some newer methods of riser removal use knockoff machinery with special designs incorporated
into the riser neck geometry that allow the riser to break off at the right place.
The gating system required producing castings in a mould yields leftover metal, including
heads, risers, and sprue, sometimes collectively called sprue, that can exceed 50% of the metal
required to pour a full mould. Since this metal must be remelted as salvage, the yield of a
particular gating configuration becomes an important economic consideration when designing
various gating schemes, to minimize the cost of excess sprue, and thus melting costs.

Heat treating:
Heat treating is a group of industrial and metalworking processes used to alter the
physical, and sometimes chemical, properties of a material. The most common application is
metallurgical. Heat treatments are also used in the manufacture of many other materials, such as
glass. Heat treatment involves the use of heating or chilling, normally to extreme temperatures,
to achieve a desired result such as hardening or softening of a material. Heat treatment
techniques include annealing, case hardening, precipitation strengthening, tempering, and
quenching. It is noteworthy that while the term heat treatment applies only to processes where
the heating and cooling are done for the specific purpose of altering properties intentionally,
heating and cooling often occur incidentally during other manufacturing processes such as hot
forming or welding.
Surface cleaning:
After degating and heat treating, sand or other moulding media may adhere to the casting.
To remove this surface is cleaned using a blasting process. This means a granular media will be
propelled against the surface of the casting to mechanically knock away the adhering sand. The
media may be blown with compressed air, or may be hurled using a shot wheel. The media

39

strikes the casting surface at high velocity to dislodge the moulding media (for example, sand,
slag) from the casting surface. Numerous materials may be used as media, including steel, iron,
other metal alloys, aluminium oxides, glass beads, walnut shells, baking powder among others.
The blasting media is selected to develop the colour and reflectance of the cast surface. Terms
used to describe this process include cleaning, bead blasting, and sand blasting. Shot peening
may be used to further work-harden and finish the surface.
Finishing:
The final step in the process usually involves grinding, sanding, or machining the
component in order to achieve the desired dimensional accuracies, physical shape and surface
finish.
Removing the remaining gate material, called a gate stub, is usually done using a grinder
or sanding. These processes are used because their material removal rates are slow enough to
control the amount of material. These steps are done prior to any final machining.
After grinding, any surfaces that require tight dimensional control are machined. Many
castings are machined in CNC milling centres. The reason for this is that these processes have
better dimensional capability and repeatability than many casting processes. However, it is not
uncommon today for many components to be used without machining.
A few foundries provide other services before shipping components to their customers.
Painting components to prevent corrosion and improve visual appeal is common. Some foundries
will assemble their castings into complete machines or sub-assemblies. Other foundries weld
multiple castings or wrought metals together to form a finished product.
More and more the process of finishing a casting is being achieved using robotic
machines which eliminate the need for a human to physically grind or break parting lines, gating
material or feeders. The introduction of these machines has reduced injury to workers, costs of
consumables whilst also reducing the time necessary to finish a casting. It also eliminates the
problem of human error so as to increase repeatability in the quality of grinding. With a change
of tooling these machines can finish a wide variety of materials including iron, bronze and
aluminium.







40

FOUNDRY TOOLS




41

































Mark Allocation
Performance 05
Observation 05
Attendance 05
Viva 05
Total 20

42

Ex. No: 14 MOULD WITH SOLID PATTERN
Date:
AIM:
To make the mould of flange pattern
MATERIAL SUPPLIED:
Mild Steel round rod of size ____________________mm

TOOLS REQUIRED:
Moulding boxes
Moulding board
Shovel
Sand rammer
Strike off bar
Vent wire
Riser pin
Draw spike
SEQUENCE OF OPERATIONS:
Boaring
Internal Thread cutting

PROCEDURE:
1. The flange pattern is placed on the moulding board
2. A suitable core is prepared and placed in the hold of flange pattern
3. Clay wishing is done inside the drag surface
4. Parting sand is applied over the pattern
5. Box is filled with smooth moulding sand and proper ramming is done using flat and peen
rammer
6. Excess sand is removed using the strike of bar

43

7. Drag is teered upside down
8. The cope is placed on the drag after doing clay wash
9. The runner and riser are placed over the pattern
10. Ramming is done to get a rigid mould
11. Using strike off bar excess sand is removed
12. Vent holes are mark using vent rod
13. Cope is kept circle and pattern is removed using draw pin
14. Gate is prepared using gate cutter
15. Cope and drag are assembled and the mould is ready for casting









RESULT:
Thus the flange moulding is prepared and ready for casting.





Mark Allocation
Performance 05
Observation 05
Attendance 05
Viva 05
Total 20

44

Ex. No: 15 MOULD WITH SPLIT PATTERN
Date:
AIM:
To make green sand mould tumblers

MATERIAL SUPPLIED:
Mild Steel round rod of size ____________________mm

TOOLS REQUIRED:
Moulding boxes
Moulding board
Shovel
Sand rammer
Strike off bar
Vent wire
Riser pin
Draw spike
SEQUENCE OF OPERATIONS:
Boaring
Internal Thread cutting
PROCEDURE:
1. Moulding sand should prepared by mixing thoroughly silica sand with required suck amount
of powder and water
2. Tumblers is placed on the moulding board and come parting sand should be sprinkled to
prevent sticking of moulding sand to the board
3. Drag box is placed on the moulding board with its dual pins facing downwards such that the
pattern should be approximately at the center of the box
4. Now the drag is rolled over on the bottom board and the cope box is assembled with the legs
engaging dowels is on the drag box parting sand should be sprinkled inside the box

45

5. Cope is separated from the drag and the pattern is drawn out carefully by using draw spike
6. Cope and drag are assembled














RESULT:
The green sand mould for tumbles pattern is made.


Mark Allocation
Performance 05
Observation 05
Attendance 05
Viva 05
Total 20